NC Engine Manual

Safety Warning
This WorkshopManual will alert you to certain procedures that

must be done very carefullyo if you ignore this information,
you could...
® injure yourself or people around you

® injure the boat operator, boat passengers, or
people around the boat
® Damagethe Volvo Penta product or its systems
Understand the following symbols before proceeding:
Alerts you to the possibility of dangerand

Z~ Safety Warning identifies information that will help pre-
vent injuries.
Identifies information that will help pre-
vent damageto machinery.
Appearsnext to information that controns

correct assembly and operation of the
product.
This WorkshopManual is written for qualified, factory trained

service technicians familiar with the use of Volvo Penta special
tools.
This Workshop Manual reins you how to correctly maintain and

service Vomvo Penta products and systems. When correctly
serviced, the Volvo Penta product will be reliable and safe to
operate.
WhenVolvo Penta special toots are called for, use them.

Where mentioned, the tools are required to perform the service
procedure.
if you use service proceduresor service tools that are not

recommendedin this manual, YOUALONEmust decided Wf
your actions might injure people or damagethe Volvo Penta
product.
Contents
General information ....................
3.0 Engine
4.3, 5.7 Engines
5.0, 5.8 FL Engines ....................
5.0, 5.8 Fi Engines
7.4, 8.2 Engines
Steering Systems
Control Systems
Cooling Systems
Engine Removal and Installation ...........
Safety ..............................
© 1996 Volvo Penta of the Americas, Inc. All Rights Reserved
i
This WorkshopManualis oneof a set of nine that coversVolvoPenta
sterndrivemodels.All ninebooks
canbeorderedas a set fromVolvoPenta
Parts. OrderP/N 7788880-8.
IndividualWorkshopManuals
covering
thesemodelsare aRsoavailable.Or-
derthe followingpart numbers
fromVolvoPentaParts.
¯ P/N 7788881-6SX, DP-SDHveUnit and Transom

Shield
Includes information on TransomShield, UpperGearUnit and LowerGearUnit
service; DriveUnit removalandinstallation; Propellers;andTrim,q~lthydraulic
operation.
¯ P/N 77888824MRDiagnostic(5.0 F~ 5.8 Fi/FSi). Ford

Includesstep by step troubleshootingprocedures
for all MFIFordrelated com-
ponentsand wiring.
¯ P/N 77888832
TBI Diagnostic(4.3 Gi, 5.7 Gi/GSi)-
Containstroubleshootingproceduresfor all TSI GMmodelsand related com-
ponents.
¯ PIN 7788884=0
MFIDiagnostic
(7.4 Gi/GSi,8.2 GSi)- GN/
Includesstep by step troubleshootingproceduresfor all MFJGMrelated compo-
nentsandwiring.
¯P/N 7788885.7SP-DPDrive Unit and TransomShield

Includes information on TransomShield, UpperGearUnit, LowerGearUnit
service; Drive Unit removalandinstallation; Propellers;andTdm/’r~fthydraulic
operationand servicing procedures.
¯ P/N 7788888=5EngineComponents
Includes information on Engineservice and troubleshooting; Engineremoval
andinstallation; Steeringsystems;Throttle
andShift Controlsystems;
andCooling
systems.
¯ P/N 7788887-3
Electrical & ignition System
Includesservice and troubleshootinginformation on Crankingsystems;Charg-
ing systems;Trim/Tilt electrical systems;Ignition systems;andEngineandIn-
strumentwiring diagrams.
¯ PiN 7788888-1Fuel System

Includesservice andtroubleshootinginformationon all carburetor,MFIandTBI
fuel systemsand related components.
, PiN 7788889=9DPX-LowerUnit and )(act TM Steering System

includes specific informationfor repair andoverhaulof the DPXLowerunit and
XactTM steering systemsnot coveredin the SPand DPWorkshop manual.
This Volvo Penta WorkshopManual
CoversThe FollowingVolvo Penta "NC’" Models
Engine
3,0 LITER 57GiPNCMCE 3868533 58FSilNCC 3868547
30GSMNCA 3868181 57GiPNCBCE 3868556 58FSiPNCD 3868537
30GSMNCS 3868181 57GiINCSCE 3868507 58FSiPNCS 3868543
30GSPNCA 3868182 57GiINCCCE 3868507 58FSiPNCACE 3868418
30GSPNCS 3868182
5.0 LITER 7.4 LATER
4.3 LITER 50FLPNCA 3868414 74GLPNCA 3868196
43GLPNCA 3868184 50FLPNCS 3868414 74GLPNCS 3868555
43GLPNCS 3868477 50FLPNCM 3868419 74GLINCS 3868283
43GLPNCB 3868566 50FiPNCACE 3868416 74GLINCC 3868559
43GSPNCA 3868186 50FiPNCSCE 3868416 74GiPNCACE 3868450
43GSPNCS 3868478 50FiPNCMCE 3868421 74GiPNCSCE 3868527
43GSPNCM 3868321 50FiPNCSCE 3868421 74GLPNCM 3868328
43GSPNC8 3868484 74GLPNCB 3868557
43GSJNCS 3868453 74GiPNCMCE 3868335
43GSJNCC 3868487 5.8 LITER 74GiPNCBCE 3868528
43GiPNCACE 3868185 58FLPNCA 3868415 74GilNCSCE 3868282
43GiPNCSCE 3868479 58FLPNCS 3868540 74GilNCCCE 3868529
43GiPNCMCE 3868320 58FLPNCM 3868420 74GSiXNCM 3868198
43GiPNCBC E 3868485 58FLPNCB 3868544 74GSiXNC8 3868558
58FLINCS 3868284 74GSitNCS 3868509
5.7 LITER 58FLINCC 3868546 74GSilNCC 3868560
57GLPNCS 3868570 58FiPNCACE 3868417
57GiPNCACE 3868429 58FiPNCSCE 3868541 8.2 UTER
57GiPNCSCE 3868553 58FiPNCMCE 3868422 82GSiXNCB 3868457
57GSiPNCS 3868564 58FiPNCBCE 3868545
58FSilNCS 3868538
Transom
Shield ..... --- - _ ............
SX-C1 3868404
SX-CLT1 3868432
SX-C1AC 3868515
DP-S 3868299
DPX-C 3868289
Sterndrive
SX-CT1 1.97:1 3868397 SXoC1 1.43:1 3868392 DP-D1 1.68:1 3868455
SX°CT1 1.85:1 3868396 DP-S 1.78:1 3868165 DPX-S 1.59:1 3868020
SXoCl 1.85:1 3868465 DP-S 1.68:t 3868166 DPX-S1 1.59:1 3868637
SX-C1 1.66:1 3868395 SX-RT1 1.66:1 3868398 DPX-S 1.68:1 3868021
DP-S 2.30:1 3868163 SX-RT1 2.18:1 3868333 DPX-Sl 1.68:1 3868638
DP-S 1.95:1 3868164 DP-C1 1.95:1 3868002 DPX-S 1.78:1 3868023
SX-C1 1.60:1 3868394 DPoD1 1.95:1 872862 DPX-S1 1.78:1 3868639
SX-C1 t .51:1 3868393 DP-D1 1.78:1 :3868022
Jet Drive
PJX-S 3868467
PJX-C 3868694
Notes
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
Section1
Generalinformation
Table of Contents
Belt Adjustments
Alternator ........................................... 1-24
Power Steering ...................................... 1-22
Raw-water Pump.................................... 1-24
Belt Tension ........................................ 1-21
CompressionPressure Limit Chart ........................ 1-7
Conversion Charts
Drill ................................................ 1-40
Metric .............................................. 1-39
Crankcase Oil .......................................... 1-9
Engine Break-in ....................................... 1-18
Engine CompressionTesting ............................. 1-5
Engine Troubleshooting Guides ......................... 1-26
Gasolines Containing Alcohol ............................ 1-8
Gasoline Requirements ................................. 1-8
Introduction ............................................ 1-2
Lubrication
Inspection Chart ..................................... 1-42
Steering System ..................................... 1-11
Off-Season Storage Preparations ........................ 1-11
Oil Filter ............................................. 1-10
Power Steering Fluid Level ............................. 1-11
PowerTrim/Tilt Fluid Level ............................... 1-11
Preparation for Boating After Storage .................... 1-17
SubmergedEngine .................................... 1-20
Symbols .............................................. 1-41
Torque Specifications, General .......................... 1-38
Troubleshooting- System Isolation ...................... 1-25
Tune-up Specifications ................................. 1-33
Tuning the Engine ...................................... 1-5
20-Hour Check ........................................ 1-20
Safety Warning
Before workingon any part of any Volvo Penta® engine, read the
section catled Safety at the endof this manual.
introduction
This workshopmanualcovers Volvo Pentastern drive models, it is
divided into sections concerning various systems and assem-
blies. Refer to the Contents to locate the section covering the
systemor assemblyrequiring service. Each section title page has
an additional listing that will describe the section’s contents in
moredetail. 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 changeat
any time, somephotos maynot depict actual product.
GoodService Practice
Service required for Volvo Penta stern drives is generally one of

three kinds:
® Normalcare and maintenance-which includes putting a

new stern drive into operation, storing engines, lubrica-
tion, and care under speciamoperating conditions such as
salt water and cold weather.
@ Operating ma|functions - due to improper engine or

drive mounting, propeller condition or size, boat condi-
tion, or the malfunction of somepart of the engine. This
includes engine servicing procedures to keep the engine
in prime operating condition.
e Complete disassembly and overhaul - such as major

service or rebuilding a unit.
It is important to determine before disassembly just whal the

trouble is and howto correct it quickly, with minimumexpenseto
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. Wearnot readily apparent on
other parts could cause malfunction soon after the repair job.
Repair kits and seal kits contain all the parts neededto 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 speciam tools are designed to perform service pro-
cedures 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 somecases, the use of substi-
tute tools can damagethe part.
Do not operate engine out of water even momentarily. If

operated in test tank, use proper test wheel=Failure to do so can
damageraw-water pump, overheat engine, or allow excessive
engine RPM.
1-2 Engineleng
Preparation for Service
Proper preparation is extremely helpful for efficient service work.

A clean work area at the start of each job will minimize tools and
parts becoming misplaced. Clean an engine that is excessiveBy
dirty before work starts. Cleaning will occasionally uncover
trouble sources. Obtain tools, instruments and parts neededfor
the job before work is started, nnterrupting a job to Jocate special
tools or repair kits is a needlessdelay.
Z/~ Use proper lifting and handling equipment. Working on stern

drives without proper equipmentcan cause damageand person-
al injury.
AJwaysuse clean fresh fuel when testing engines. Troubles can

often be traced to the use of old or dirty fuel
Service PoJicy
Whetherwithin or fonlowing the warranty period, Volvo Penta has

a constant interest in their products.
it is Volvo Penta’a policy to provide dealers with service knowl-

edge so they can give professional service demandedby today’s
consumer. The Volvo Penta Service Schools, frequent mailing of
Service Bulletins, Letters and Promotions, Special Tools and this
WorkshopManual represent Volvo Penta’s efforts to assist deal-
¢;rs in giving consumers the best and most prompt service
possible. This WorkshopManual covers all phases of servicing
the Volvo Penta stern drive 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 Volvo Penta’s Warranty. if you
have any questions, write the Volvo Penta Service Department. If
other than genuine Volvo Penta repJacement componentsor parts
are used, Volvo Penta may refuse subsequent warranty claims
involving that engine.
Whena brand-nameproduct or specific too[ is called for, another

item maybe used.. However, the substitute must have equivalent
characteristics, including type, strength, and material You must
determine if incorrect substitution could resuJt in product mal-
function and personal injury to anyone. To avoid hazards, equiva-
lent products which are used must meet all current U.S. Coast
Guard Safety Regulations and ABYCstandards.
Replacement
Parts
Whenreplacementparts are required, always use genuine

VolvoPentaparts, or parts with equivalentcharacteristics, in-
cluding type, strength, andmaterial. Failure to do so mayresuh
in productmaifiJnc~onandpossibleinjury to the operatorand/or
passengers.
Parts Catamogs
Z~ Parts Catalogsare a goodsourceof information for ordering

parts. Theyare NOTa good source for disassemblyand reas-
sembly of the engines and drives. Theexpnododviews in the
Parts Catalogsare for illustration of parts only, not a sourceof
assemblyinstructions. Theworkshopmanualhas detailed infor-
mationandis the only sourceof information for disassembHy and
reassembtyo
Fa#ureto follow wodrshopmanualproceduresand

cautions mayresult in death, personal injury to
yourself or bystandersand damaged equipment.
Special Service Tools
VolvoPentahas specially designedtools to simpJify disassembly

andreassemblyoperations. Thesetools are illustrated in this
Workshop ManualAll Volvo Penta special tools can be ordered
from Volvo Penta Parts Department.Non-dealerusers of Work-
shopManualsmust order Special tools through and authorized
Volvo PentaDealer.
ProductReferences,Illustrations andSpecifications
VolvoPentareservesthe right to makechangesat anytime,with-
out notice, to specifications, models,andprocedures.Also, the
right to changeany specifications or parts at any time without
incurring any obligation to equip sameon modeRs manufactured
prior to date of suchchange.All information, illustrations and
specifications, containedin this manualare basedon the latest
productinformationavailable at the time of printing. Theright is
reservedto makechangesat any time without notice.
Photographs
andillustrations usedin this manualmaynot depict
actual modelsor equipment.The continuing accuracy of this
manualcannot be guaranteed.
Safety Re|ated 1-4 Engineleng

TuningThe Engine
Thepurposeof an engine tune-upis to restore powerand perfor-
mancethat has beenlost throughwearanddeterioration of oneor
more components.In the normal operation of an engine, these
changes can take place graduallyat a number of points, it is seldom
advisableto attempt improvement in performanceby correcting one
or two items only. Lasting results will be obtainedby following a
definite andthoroughprocedureof analysis andcorrecting all items
affecting powerand performance.
Economical, dependableoperation can be ensured if a complete
tune up is performedonceevery boating season,preferably at the
beginning of the seasonwhenboat is brought out of off season
storage. Components that affect powerand performancecan be
divided into three groups:
e Components
affecting compression
eComponents
affecting ignition
¯ Components
affecting fuel system
Proceduresfor performinga completeengine tune-up will be cov-
eredin this manual.
Engine CompressionTes~ng
1. CompressionCheck:Proper compressionis essential for good
engine performance. An engine with low or unevencompression
cannotbe properly tuned.
&WARNING Useextremecare aroundenginewh#erunningor crank-
ing. Removeloose clothing and jewelry to prevent
entanglementwith rotating pulleys and drive ~ts.
a. Runengine up to normaloperating temperature.
[~ Engine must NOTbe started and run without water for
cooling.
Er,~=,~ng ~ Safety Related 1-5

b. Remove any foreign matter from aroundspark plugs by blowing
out with compressedair.
~WARN~G Wearhearing and eye protection whenusing corn
pressed air
c. Remove
andinspectall sparkplugs.Install thread-typecompres-
sion gaugein sparkplughole.
d. To PreventSparking:
¯ 3.0GS, 4.3GL, GS, 4.3, 5.7, 7.4, 8.2Gi, andGSi

Modens- remove (pink and brown) 2-wire connec-
tor from ignition coil. Onall modelsexcept 3.0
GS models, removeelectric fuel pumprelay
°5.7,7.4GLw/o E.E.M.,and 8.2GL, 5.0 and 5.8 FL
Models - removeboth distributor primary wires
fromthe ignition coil, and tape wire terminansto
prevent accidental grounding.
7.4 GL with E.E.M. Models - remove14 wire con-
nector at the ignition module. Removeelectric
fuel pumprelay.
® 5.0 and 5.8 Fi, FSi Models- Unplug 2-way connec-
tor at ignition coil.
e. Withchokeandthrottle plateswideopen,crankenginethroughat
least four compression
strokes, Carbureted
modelsonly.
Test Conclusion
Theindicated compression pressuresare considerednormalif the nowest

readingcylinderis within 75%of the highest.
Example
If the highestpressurereadingwas140PSI, 75%of 140is 105. Therefore,

anycylinder readingless than105PSiindicatesanimproperlyseatedvalve,
wornvalveguidesor wornor brokenpiston rings. Anycylinder reading105
PSior greateris within specifications,andcompression
is considerednor-
mal.
If oneor morecylinders readlow, squirt approximately onetablespoonof

engineoil on top of the pistonsin the low readingcylinders. Repeatcom-
pressionpressurecheckon the cylinders.
1. If compression
improves
considerably,
the pistonrings are at fault.
2. If compression
doesnot improve,valvesare stickingor seatingpoorly,or
valveguidesare worn.
3. ff twoadjacentcylindersindicate low compressionpressuresandsquirt-

ing oin on the pistonsdoesnot increasethe compression,the causemaybe
a cylinder headgasketleak betweenthe cylinders. Thisproblemcouldallow
engineoil and/orcoolantto enterthe cylinders.
SafetyReJated 1-6 Engine/eng

it is recommendedthe following quick reference chart be used when checking cyninder compression
pressures. The chart has been calculated so that the lowest reading number is 75%of the highest
reading.
CompressionPressure Limit Chart
Max. Min. Max. Min. Max. Min. Max. Min.

PSi PSI PSm PSI PSI PSi PSI PSI
134 101 154 115 174 131 194 145

136 102 156 117 176 132 196 147
138 104 158 118 178 133 198 148
140 105 160 120 180 135 2OO 150
142 107 162 121 182 136 202 151
144 108 164 123 184 138 2O4 153
146 110 166 124 186 140 206 154
148 111 168 126 188 141 208 156
150 113 170 127 190 142 210 157
152 114 172 129 192 144 212 158
After checking cylinder compression, repairs should be madeas

necessary. Subsequent adjustments to an engine that does not
have proper compression will not measurabmyimprove perfor-
manceor correct operational problems. After verifying compres-
sion, check ignition and fuel system components.
¯ Spark Plugs ¯ Fuel Tank Pickup and Screen

¯ Spark Plug Leads ® Fuel Tank Vent
e Distributor Cap ¯ Anti-Siphon Valve (if equipped)
¯ Rotor ¯ Fuel Octane and Quality
¯ ngnition Coil ¯ Boat Fuel Lines and Valves
¯ High Tension Lead ¯ External Engine Fuel Fimter
¯ ignition Switch ® Fuel Pumpand Line
¯ Circuit Wiring and Connectors ¯ Carburetor Fuel Filter or Screen
o ECM ® Carburetor Adjustments
¯ Engine PCV"valve (if equipped)
¯ Flame Arrestor
¯ Pressure Regulator and injectors
® TBI Unit
All of the abovelisted componentsare not necessarily part of an

engine tune-up, but must be considered when attempting to
correct engine/boat performance problems. Repair or repmace
componentsonly as required.
Z~ Do not substitute automotive parts. Volvo Penta marine

componentsmeet U.So Coast Guard reguJations for external
ignition proof operation and marine use. Volvo Penta marine
components are specially designednot to causeignition of fuel
vapors in the bilge or engine compartment.The use of a,utomo-
rive parts canresuKtin fire and explosion.
Eng~..;o.~ L~ Safety Related 1-7

Gasoline Requirements
Volvo Penta engines are designed for maximum performanceus-

ing gasoline with the following minimum
octanespecifications:
¯ Anti-knock Index Number(AKI) -

¯ Research Octane Number(RON) -
4.3 GL, GSModels: Theignition timing mustbe retarded if fuels

are usedwith less than 86 AKI (90 RON)octaneare used. Refer
"Timing and Fuel Requirementsin the Tune Up Section of this
manualfor details. Whenignition timing is retarded, a slight de-
crease in performancecan be expected.
,~ Use of gasoline with lower than 89AKI (93 RON)octane

4.3 modelengines, without retarding ignition timing as specified,
will result in seriousdamageto your engineandwill void the engine
warranty.
Fuel injected Models:Every attempt should be madeto use un-

leadedfuel, however,somemarinasonly sell fuel with lead addi-
tives. If unleaded
fuel is unavailable,the substitution of leadedfuel
for temporaryuse will not harmthe fuel system. Premiumgrade
fuels containinjector cleanersandother additives that protect the
fuel systemand provide optimumperformance.Theuse of premium
grade fuels is strongly recommended. Do not use leadedfueJ in
Certified Emission engines.Leadedfuel will void the certifica-
tion of emissions.
CarburetedModels:Useof lead-free or leaded gasoline is ac-

ceptable.
¯ ]
LN°tej Engine damageresulting from the use of gasoline with
octane lower than 87 AKI (91 RON)is considered misuse of the
engine and will void the engine warranty. Volvo Penta suggests
the use of 89 AKI or higher fuels. Thesefuels haveadditives that
are beneficial to maximumengineperformance and long life of ser-
vice components.To prevent gumformation and corrosion in the
fuel system, use Volvo PentaFuel SystemCleanerin the gasoline.
Volvo Penta Fuel systemCleaner is available through your Volvo
Pentadealer.
~ Gasoline is extremely flammable and highly explosive under

certain conditions. Alwaysstop engine and do not smokeor allow
openflames near the boat whenrefueling. Whenfueling, always
groundthe tank to the fuel sourceby holdingthe hosenozzlefirmly
againstthe side of the deckfiller plate, or groundit by someother
means.This action preventsstatic electricity buildup whichcould
causesparks and ignite fuel vapors.
SafetyRelated 1-8 Engine/eng

See the boat’s Operators Manual to determine if the boat’s fuel
system is compatible with alcohol blended fuels. If it is, your
engine may use gasolines blended with no more than 10%
Ethanon (ethyl alcohol) meeting the minimumoctane specifica-
tion. Do not use any gasoline which contains METHANOL I[rneth-
yJ alcohol).
Continued use of METHANOL (methyl alcohol) fuel will

cause serious damageto the boat or engine fuel systems.
ff you use gasoline containing alcohol, be awareof the folk)wing:
@ The engine will operate leaner. This may cause engine

problems such as vapor lock, low speed stalling, or hard
starting.
@ Alcohol blended fuels attract and hold moisture. Mois-

ture can cause fuel tank corrosion. Inspect fuel tanks at
least annually. Replacecorroded or leaking fuel tanks.
Frequently inspect non-metallic parts of fuel system and

replace if excessively stiff, deteriorated or leaking.
leakage can contribute to a fire and/or explosion.

DR2511
CrankcaseOil
J._l~ initial factory fill is a high quality motor oil for AP! Service
SG/CD.During the break-in period (20 hours), frequently check
the oil level. Somewhathigher oil consumption is normal until
piston rings are seated. The oil level should be maintained in the
safe range between the Add and Full marks on the dipstick. This
range represents approximately 1 liter (1 quart), if it is necessary
to add or changethe motor oil, use a quality oil with APi service
category SG/CDthat meets General Motors Standard GM-6094-M
or Ford Specification ESE-M2C153-E.Volvo Penta DuraPlus TM
Motor Oils are recommended.
At the end of the break-in period (20 hours), changethe crankcase

oil and replace the oil filter. Refer to LubricationandInspection
Chart for recommendedoil change intervals,
[~ The use of multi-viscosity oils, such as 10W=30or 10W-40,

is not recommended.
Draining and Riling the Engine Crankcase
Drain and refill crankcase every 100 hours of operation or once a

,season, whicheveroccurs first.
Z~ To prevent fire and explosion, always make sure engine

compartmentis free of gasoline fumes before using any spark-
producingtools such as the electric drill motor usedwith oil
withdrawal pumpkit. Fire and explosion can result in personal
injury.
[~ ""~[~ Check the motor oil frequentJy. Whenoil is to be
changed,removedipstick anddrawoil from crankcasethroughdip-
stick tube with a suction pump.Thedipstick tube is intendedto be
usedfor drainageof the engineoil so it will not haveto be drained
into the bilge.
Fill the crankcaseto recommended capacity with a quality motoroil

labenedfor SAEservice category SGwhich meetsGeneral Motors
Standard GM-6094-M or Ford Specification ESE-M2C153-E. Oils
conformingto this standardcontain detergent and anti-wear addi-
tives that will prolong enginelife. Volvo Penta DuraPlusTMSyn- 34089
thetic Motor Off P/N 3851230-7exceedsboth manufacturersstan-

dards.
When changingmotoroil, select the viscosity that matchesthe tem-

perature range in which the boat will be operated. Usethe same
viscosity whenaddingmotoroil, do not mixdifferent viscosity oils.
LowestAnticipated SAEViscosity I
Temperature OB Recommended
341O1
32°F(0°C) and above SAE30
I 0°F(-18°C)to 32°F(O°C) SAE20W-20
L Below0°F (-18°C) SAE10W
~,CAUTION: Donot fill abovefull mark.Overfilling results in high

operatingtemperatures,foamingthe oil (mixingair in the oil), loss
of power,andreducedenginelife.
CrankcaseCapacities
34164
Model LessFilter WithFilter

3.0 GS 3.5qts. (3,3 liters) 4.0qts. (3,8liters)
4.3 GL, GS,Gi 4.0qts. (3,8 litres) 4.5 qts. (43 litres)
4.3 GL, GS,Gi 2 4.5qts. (4.3 litres) 5.0qts. (4.7liters)
5.0 FL 5.0qts. (4,7 litres) 6.0qts. (5,7litres)
5.7 GL,Gi 5.0qts. (4,7 litres) 6.0qts, (5,7litres)
5.8 FL 5.0qts. (4,7 litres) 6.0qts. (5,7litres)
5.0 Fi 5.0qts. (4,7 litres) 6.0qts. (5,7litres)
5.8 Fi, FSi 4.0qts. (3,8 litres) 5.0qts. (4,7 litres)
7.4 GL 5.0qts. (4,7 litres) 6.0qts. (5,7 Witres) 29712
7.4 GL3 8.0qts. (7,8 litres) 9.0qts. (8,5 litres)
7.4 8.2 Gi, GSi 8.0qts. (7,6 litres) 9.0qts. (8,5 fitres)
2 with ribbed aluminumoil pan

3 with aluminumtiming chain cover
1-10 DR2497
Engme/eng
Oil Filter
r~ Replace the oil filter wheneverthe motoroil is changed.Thisfilter is

a self-contained,screw-on type. Toremove, unscrew filter canistercoun-
terclockwise anddiscard.When attachinga newfilter, be surethe gasket
is lightly lubricatedwith motoroil. Handtighten only, run engineand
checkfor leaks. Donot run enginewithout supplingcoolingwater.See
Tune-up Specificationsfor modelandfilter requirements.
PowerSteering Ruid Level
L~ [~ Maintainthe level with VolvoPentapowertrim/tilt & steering 24674
fluid. Approvedpowersteeringfluids suchas GMpowersteeringfluid or

Dexron II automatictransmission
fluid canalso be used.Donot overfill
the pump reservoir.
Steering SystemLubrication
L~ [~ Every 60 days, greasethe steering ram ® with Volvo Penta

Grease.
PowerTrim/Tilt-Fluid Level COA6781A
LL~At the beginningof eachboatingseason,checkthe fluid level in the

reservoirasfollows:
~,CAUTION ¯ The trim/tilt hydraulics are pressurized whenthe

drive unit is in the downposition. Thedrive unit mustbe tillted full
up to relieve hydraulic pressurebefore removinglevel/fill plug ~.
Failure to tilt the drive unit to the full up position beforeremoving
level/fill plug wouldresult in a hazardous spray of hydraulic oil.
Caution should always be taken whenremovinglevel/fill plug by
placing a rag over the level/fill plug to preventresidual pressure 3253
fromsprayingoil.
1. Withthedriveunit tilted full up,slowlyandcarefullyremove

thelevel/fill
plug.
2. Check thefluid level. Thefluid shouldbelevel withthebottom of thefill

,holewhen thedriveunit is at full tilt. If necessary,addVolvoPentapower
trim/tilt &steeringfluid. Replace thelevel/fill plugandtightensecurely.
Off-Season Storage Preparations

29819
,Step 1. ConditionFuelSystem:
AddFuelConditioner
to fuel system.
Followinstructionsfor adding
condi-
tionerandrunning
engineasstatedonthecontainer.Thiswill stabilizethe
fuet andprevent
formation
of varnishandgum in entirefuel system.
Dothis
beforecontinuing
withthefollowingprocedures.
~N~°te 1 Modelsequippedwith 4 BBLcarburetorsshouldbe run undera

loadat a highenough throttle setting to circulateconditionerthroughthe
secondary fuel system.
E,~+~-~ ~ Safety Related 1-1 1 199O3
Step 2- ChangeMotor Oil end Oil Fiker:
Engine shouEdfirst be operated under load until oil is

thoroughJy warmed up. if oil is allowed to warm up
before draining, a more complete draining wile be ac-
complished, in addition, accumulated impurities wilJ be
held in suspension by the oil and be removed during
draining operation.
Removemotor oil by siphoning it out of oil withdrawan

tube. Follow the procedure under Draining and Filling
the Engine Crankcase.
Install a new oil filter and fill crankcase with recom-

mendedoil. With drive unit in full down position, run
engine at a fast idle for a few minutes to distribute clean
oil through engine.
Shut off engine and checkoil level. Checkoil filter gasket

for leaks. Addoil if necessaryto bring oil level up to, but
not over, the full mark.
Drive unit must be submergedin water or an accessory

flushing adaptor must be used while operating engine.
Z~ Whenusing a flushing adaptor, removepropeller before

starting engine to prevent accidental contact with moving
propeller, if propeller is not removed,personal injury may
result.
Step 3. ChangeDrive Unit Lubricant:
Drain and refill with fresh DuraPlussynthetic GL5gearoil. Refer

to Drive Unit WorkshopManual.
Step 4. Fog Engine:
Carbureted and TB! Models
® Warmup engine to ensure fuel conditioner is throughout

fuel system. Use 1/~ pint (0,24 litre) of FoggingOil or
oz. (355 ml) spray can to fog engine.
@ Removeflame arrestor from carburetor. Following in-

structions on container, bring engine up to a fast idUe and
stowly pour or spray % of fogging oil into carburetor.
Keep engine running whiJe pouring fogging oil into
carburetor throat.
@ Rapidly add remaining I/3 of fogging oil to carburetor,

then reduce throttle to idle and let engine die. Turn off
ignition and replace flame arrestor. Close fuel shutoff
valve (if so equipped).
Safety Related 1-12

1. Preparing anengine"storage mixture"in a six gallonfuel tank.It mustcon-
sist of a 5 gallons
(18,9liters) fuel; 4 pints(64oz., 19ml)Fogging Oil; and
cup(2.5oz., 73.9ml) FuelConditioner. Mixtheseingredients thoroughly.
2. Disconnect
fuel line at theengine.Connectthe"storagemixture"anclrun
enginefor approximately
5 minutes
at 1500RPM. Thiswill ensure
that all fuel
systems andinternal enginecomponentsare thoroughlyprotected.Shutoff
enginebeforethe"storagemixture"is depleted.
19efoO
~CAUTION Do not FogFi andFSi enginesthroughthe air intake. The
throttle plateshavea specialcoating,fogging
oil will damage
thecoating.
Step5. DrainCoolingSystem:
,&.CAUTION Whendrainingengine,raise or lowerthe bowtopositionengine

in a horizontalplane.Thiswill providefor complete drainage
of blockand
manifolds.If bowof boatis higheror lowerthanstern, some watermaybe
trappedin the engineblockor manifolds.Improper
or incompletedrainingmay
result in freezedamageto the engine,manifolds,
driveunit or othercornpo-
nents. Freezedamage is not covered underVolvoPenta’slimited war- 23913
ranty°
Front
OLoosenandslide clampback.Remove
anddrain long hoseat thermostat
housing.
Starboard 28288
®Disconnect
andrain largehoseat circulating pump.
~.J Port
® Removeexhaustmanifoldpetcockstem.Clearhole with a smallwire to
ensurecompletedrainage.
® Removecylinder block petcockstem.Clear hole with a small wire to
ensurecompletedrainage.
34093
El Front
¯ Disconnect
anddrain long hoseat thermostathousing.
®Disconnect
anddrainlarge hoseat circulating pump.
Disconnect
the waterbypass hoseat thelargediameter
endof the checkvalve.
Drainor blowout check,valve
andshorthoseto thermostat
housing.Dra:inor
blowoutlonghoseto fuel resovoir.
E.Q;~e,~ 1-13
[~] Starboard
® Loosen clamp and remove hose.

® Removecylinder block petcock stem. Clear hole with a small
wire to ensurecompletedrainage,
~[] Port
® Loosen clamp and remove hose.
® Removecylinder block petcock stem. Clear hole with a small
wire to ensurecompletedrainage. 34O91
| . o : ®e" Q
[~ Front
(~ Disconnect the lower water bypasshose at large diameter of

check-valve.
¯ Drain or blow out check-valve and short hose to

thermostat housing.
34102
® Drain or blow out long hoseto fueJ reservoir.
[~ Front
® Disconnect and drain long hose at thermostat housing.
® Disconnectan drain large hose at circulating pump.
[~ Starboard
34161
® Loosen clamp and removerubber hose.

Removecylinder block petcockstem. Clear hole with small wire
to ensurecompletedrainage.
1 ®1 4 Engine/eng
I~ Starboard
® Loosen hose clamp and remove rubber hose.
® Remove cylinder block petcock stem. Clear hole with a small
wire to ensurecompletedrainage.
r~ Port
® Loosen clamp and remove rubber hose.
34179
I~ Front
0 Disconnectand drain long hose at thermostat housing.

® Disconnectand drain large hoseat circulating pump.
Disconnect the water bypass hose at the large end of the

checkvalve.Drain or blow out checkvalveand short hoseto ther-
mostathousing.Drain or blowout long hoseto fuel resovior.
[~ Starboard

[~ Port 28251

Removecylinder block petcock stem. Clear hole with a small
28283
28284
Englne/eng 1- 1 5
co- 0 ®® -
OnModelsequippedwith oil coolers, removelowest water hose

from cooler. If cooler is mountedhorizontally, removeone water
hose® from oil cooler, loosen mountingbolt ®, and tip oil cooler
downward to drain.
+ + ~ o
ee" ~ e_
Loosenand slide hose clamps back. Removehoses from the 21122
rear of the raw-water pumpand drain. Crank the engine no more

than 2 seconds(DONOTSTART) to expel any water trapped in the
raw-water pump.Reinstall raw-water pumphoses.
Step 6. Drain Pivot Housing:
[~] Todraincavity in pivot housing,tilt drive unit to the full tilt (up)
position and removethe water drain plug @from the port side of
the pivot housing.Tilt the drive unit to the full downposition. Allow
unit to drain. After unit has completelydrained, replacepivot hous-
ing plug. Inspect drive unit water intake screenfor obstructions. 33857
,&CAUTION Failure to completly drain the cooling systemwill re-

suit in serious damageto the engine, exhaustmanifolds,andstern-
drive whentemperaturego belowfreezing. If completedrainageis
in doubt, checkdrain openingwith a small piece of wire.
Step 8. Disconnect the Battery and place in storage. When

storagewill be for a considerable
lengthof time, periodically
rechargethe battery following the manufacturer’s
recommendations.
34087
Step9. SprayEntire EngineandDrive Unit With Volvo Penta

TMCorrosionShield. Followdirections on the
DuraPlus
container.
1-16 Engme/eng
Preparation for Boating After Storage
11. install stemsand close all drain petcocks. Install cooling hoses
and clamps. Check condition of hoses, manifold end cap,s and
clamps. Connect hoses to engine and tighten clamps sec.urely.
install boat drain plug, if removed.
2. Removethe distributor cap and rotor. Wipe the inside of the

distributor cap dry with a clean cloth and spray with Dura Plus
Corrosion Shield or equivalent. Replace the rotor and cap.
3. Clean the battery terminals. With the ignition switch in the

"OFF"position, install the battery and attach the battery cables.
Spray terminals with Dura Plus Corrosion Shiled or equivalent.
Z~ 4. Openthe fuel shut-off valve (if so equipped) and check a|l

fuel line connections for leaks.
5. Checkthe flame arrestor and clean if necessary. Reinstall,

makesure all parts are in place and tighten nut securely.
6. Makea thorough check of the boat and engine for loose or

missing nuts and screws. Pumpthe bilge dry and air out the
engine compartment.
Safety Warning
To prevent a possible explosion, operate the blower as

recommended by the boat manufacturer before starting
engine, if the boat is not equippedwith a bilge bllower,
open engine cover or hatch prior to starting and leave
openuntil after engine is running.
¯ if operating boat in water, tie boat securely to prevent

forward or backward movement.
Whenusing a flushing adaptor, remove the propeller

before starting engine to prevent accidental contact
with moving propellero if propeller is not removed,
personalinjury mayresult.
7. Test run engine: Launchboat or use a flushing adaptor installed

on drive unit.
[~ Do not start engine out of water unless using a flushing

adaptor. Always turn water on before starting engine. Control
water pressure as full water pressure may cause damage to
raw-water pump and engine.
~ 8. With engine compartment open, start the engine. Monitor

the voltmeter, oil pressure and water temperature gauges fre-
quently to be sure all systems are operating properly. Checkfor
fuel, oiJ, and water leaks.
Engine Break-in
All Volvo Penta stern drive engines have been run for a short
period of time as a final test at the factory. You must follow the
EngineBreak-in procedure during the first 20 hours of operation
to ensure maximumperformance and longest engine Rife.
To ensure proper lubrication during the break-in period, do

not removefactory break-in oiU until after the 20-hour break-in is
completed.
For the first five to ten minutes of operation, operate engine at a

fast idle (above 1500 RPM). After engine has reached operating
temperature, momentarily reduce engine speed, then increase
engine speed, to assist break-in of rings and bearings.
During the remaining first two hours of operation, accelerate to

bring boat onto plane quickly and bring throttle back to maintain
a planing attitude. During this period, vary the engine speed
frequently by accelerating to approximately three-fourths throttme
for two to three minutes, then back to minimumplaning speed.
Maintain planing attitude to avoid excessb#eengine load.
DO NOT RUN ENGINE AT A CONSTANTRPM FOR PROLONGED

PERIODS OF TiME DURING THE BREAK-IN PERIOD.
During next eight hours, continue to operate at approximately

three-fourths throttle or less (minimum planing speed). Occa-
sionalty reduce throttle to idle speedfor a cooling period. During
this eight hours of operation it is permissible to operate at full
throttle for periods of less than two minutes.

PERIODS OF TiME DURING THE BREAK-IN PERIOD.
During the final ten hours of break-in, after warming engine to

operating temperature, it is permissible to operate at full throttle
for five to ten minutes at a time. Momentarity reduce then
increase engine speed to assist break-in of rings and bearings.
Occasionally reduce engine speed to idle to provide cooling
periods.
1 - 18 Engine/eng
PERIODS OF TiME DURINGTHE BREAK-IN PERIOD.
During break-in period, be particularly observant during initial

running of engine, as follows:
1. Checkcrankcaseoil level frequently. Maintain oil level in safe

range, between "add" and "full" marks on dipstick.
if you have a problem getting a good oit level reading on

dipstick, rotate dipstick 180° in tube.
2. Watchoil pressure gauge. If indicator fluctuates wheneverboat

attitude (i.e. turning, climbing on plane, etc.) is changed,it may
be the oil pickup screen is not covered with oil. Checkcrankcase
dipstick, and add oU to crankcase if required. DONOTOVEIRFILL
If oil level is correct andcondition still exists, checkfor possible
gauge or oil pumpmalfunction.
[~ Oia pressure will rise as RPMincreases, and fall a.,~ RPM

decreases. In addition, cold oil will generally showhigher oil
pressure for any specific RPMthan hot oil. Both of these condi-
tions reflect normal engine operation.
3. Watchengine temperature indicator to be sure there is proper

water circulation.
Failure to follow the break-in procedure will void the

engine warranty.
At end of break-in period (20 hours}, removemotor oil and replace

oil filter. Fill crankcase with recommendedmotor oil.
Operation After Break-in
After break-in, the engine can be operated at any RPMfrom idle to

full throttle. However, cruising at 3600 RPMor less saves fuel,
reduces noise, and prolongs engine life.
Whenstarting a cold engine, always allow engine to warm up

gradually. Never run engine at full throttle until engine is thor-
oughUywarmedup. Be sure to check oil level frequently during
the first 50 hours of operation, since oil consumptionwill b,e high
until piston rings are properly seated.
Submerged
Engine
Remove
engine from water as quickly as possible.
Youmu~removeall water from the engine immediatelyand lubri-
cate all internal parts. All electrical components
mustbe dried and
inspectedfor ’water damage.Anydelay will allow extensiveengine
damage.
Frequently check engine compartmentfor gasoline fumesand ex-
cessive water accumulationin the bilge. Waterdepth in the bilge
should be kept well belowthe flywheel housing.
Volvo Penta DEALER

Service - 20-HourCheck
20-HourCheckincludes:
1. Change
engineoil andoil filter.
2. Drainandrefill drive unit. Check
the trim/tilt reservoirfor proper
fluid level.
Z~ 3. Lubricate steering cable ramwith Volvo Penta grease and,
modelsequipped with powersteering, check pumpreservoir for
correctfluid level.
5. Checkignition timing.
6. All modelsexcept MFIandTBI, checkand adjust carburetor for
correct idle mixture andidle RPM.
7. Inspect exhaustsystemandtighten all hoseclamps.
8. CheckaH engine mountscrews for correct torque and engine
alignment.
9. Lubricategreasefittings on transomshield (see appropriateDrive
Unit Manual}.Lubricste both U-joint greasefittings on drive unit -
SX modelsonly.
10. Checkfor any deficiencies, malfunctions,signs of abuse,etc.
Correctionof any problemsat this time will preventmajorprobJems
later.
11. Change
fuel filter/water separator.
12. Makesure engine can achieve maximumrated RPM.
U.S., Canada,and Mexico: Boat ownerpays for the 20-HourCheck
and is performedby the Volvo PentaDealer.
All other markets:Seewarrantypolicy for Importers.
Safety Related 1-20 Engine/eng

Belt Tension
¯ 3.0 GSModels
® 4.3, 5.7 GL, GS,and Gi Models
e 5.0, 5.8, FL andFi Models
¯ 7.4 GL, Gi, GSi and 8.2 GLModels

DR4933
¯ 3.0 GSNonpowersteering Models
¯ 4.3 PJX Models
~) PowerSteering PumpBelt
@) AlternatorBelt
(~) Raw-waterPumpBelt
EI~E~ With engine stopped, belts should be tight enough

so that it will deflect 1,4" to 1/2" (6 - 13 ram)whenpressed’with
finger at the point indicated. Alternate method,use Volvo Penta DR4935
special tool 1159660-8 andtighten belts to 20 - 25 kg (44 - 55 Ibs.).
If beJtsare too tight, excessivebelt andbearingwearcanoccur. If
they are too loose, slippagecan occur, resulting in excessivebelt
wear, poor circulation pump,raw-waterpump,and or powersteer-
ing performance.Tensionof a newbelt shouJdbe checkedafter 10
hoursof service andevery 50 hoursthereafter.
DR4934
E,,gi.~/~.~ 1-21
PowerSteering PumpBelt Adjustment
¯ 3.0 GS Models [~ ® ®
¯ 4.3, 5.7 GL, GS, and Gi Models
¯ 5.0, 5.8, FL and Fi Models

¯ 7.4 GL, Gi, GSi and 8.2 GL Models [~
(~ PowerSteering PumpPulley
® Circulating PumpPulley 33
® 1/~,, to 1/2" (6 - 13mm)Deflection
i Note Improper powersteering belt adjustment will cause a

loss of powersteeringassist, resulting in hard steering.
[~="’~’[~ Check power steering belt tension ® midwaybe-

tweenthe circuFating pumppulley ® and the powersteering pump
pulley ~).
DR4935
~] DE] To increasebelt tension: - Loosennut on lower pivot

bolt, and loosen screw on brace behind pulley. Place a 1/2"
breaker bar into the squarehole in the pumpmountingbracket,
and pivot pumpawayfrom engine as shown. While maintaining
pressure on pump,retighten all mountingscrews. Recheckbelt
tension.
~CAUTION Neverpry againstthe pump

reservoiror pull filler
neck.
DR49~
,El~LeLl~e~,"lemicril~
~’w4elt¯tclt ~
F~ r~ To increase belt tension: - Loosen pumpmounting

bracketscrews,insert a 1/2 in. breakerbar into squarehole in the
pumpmounting bracket, and pivot pumpawayfrom engine as
shown.While maintainingpressureon pump,retighten all mount-
ing screws. Recheckbelt tension.
,~CAUTION Neverpry againstthe pumpreservoir or pull filmer

neck.
16O67
1-22 Engine/eng
[3-~ F’~ To increase belt tension: Loosennut on lower pivot
bolt, andloosenscrewon bracebehindpulley. Placea 1/2" breaker
bar into squarehole in the pumpmountingbracket and pivot pump
a.way from engine as shown.While maintaining pressure on pump,
retighten all mountingscrews.Recheckbelt tension.
~CAUTION
Neverpry against the pumpreservoir or pull filler
neck. 23910
L~ r-~ To increase belt tension: Loosenpumpmounting bracket

screws. With a long pry-bar, pry against corner of timing chain
cover and tab on pumpmountingbracket. While maintaining pres-
sure on bracket, tighten screwclosest to tab. Tightenthe remaining
screws. Recheckbelt tension.
ACAUTION
Neverpry against the pumpreservoir or pull filler 24278
neck.
15930
1~901
Engineleng 1-23
Alternator Belt Adjustment
¯ 3.0 GS Models [2[3

¯ 3.0 GS NPSModels [33
o4 .3, 5.7 GL, GS, and Gi Models [2]
e4 .3 PJX Models
o5 .0, 5.8 FL and Fi Models EEl

o7 .4, 8.2 GL, Gi and GSi Models EEl
Crankshaft Pulley
® Circulating PumpPulley
® Alternator Pulley
® ~/~" to 1/2" (6 - 13 mm)Deflection
® Raw-water PumpPulley
E~,~[~ Check alternator belt tension ® midway between

the circulating pumppulley ® andthe alternator pulley ®.
1. Loosenalternator mountingscrewsand nuts, pivot alternator

awayfrom engineto increase belt tension.
2. Whilemaintainingtension on alternator belt, tighten top screw,

bottom screw and nut. Recheckbelt tension.
Thebelts usedfor the alternator, circulating pump,andpower

steering pumpare heavy-duty. DONOTreplace with automotive
belts.
Raw- Water PumpBelt Adjustment
t~e c....~,E~ Checkraw-water pumpbelt tension midwaybetween

irculating pumppulley ® and the raw-water pumppulley ®.
Loosenmounting bracket to raw-water pumpscrews, pry raw-wa-

ter pumpawayfrom engine to increase belt tension. While main-
taining pressure on raw-water pump, retighten top and bottom
screws. Recheckbelt tension.
1- 24 Engine/eng
oubieshooting - SystemIsoRation
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.
m
Engine should crank at specified RPM. If not, check
for:
Cranking
System 1. Discharged or dead battery
2. Loose or corroded connections
3. Cranking System Troubleshooting Chart in the
Eiectri¢,,ai WorkshopManual
Must have good spark at spark plugs, if not, check the:
Engine 1. Distributor cap and rotor

Does Not 2. Coil and spark plug leads
Run 3. ignition~ timing
4. Automatic spark advance
5. Appropriate ignition Troubleshooting Chart
in the Ignition Workshop Manual
Non-EF! Models: Carburetor accelerator pump shouRd

squirt fuel into venturi whenthrottle is advanced,if not,
check the:
Fuel
System 1. Fuel tank, valves, and lines
2. Fuel pumpand filter
3. Carburetor and filter
Check the following"
Compression
2. ignition system
3. Fuel and carburetor/injector system
Engine Runs 4. Lubrication system
Improperly 5. Cooling system
6. Drive unit and propeller
7. Drive unit gear ratio and installation
8. Engine Troubleshooting Guides
Engine Troubleshooting Guides
Gi, GSi, Fi, FSi: Refer to the appropriatefuel injection Diagnostic

Service Manual.
Theseguides werewritten to help you trace the symptoms of the

trouble to the source, without having to read throughand prove
everypossibility. Muchof the informationherewill be familiar to
well informed mechanics.
Atso, manyfactors will seeminsignificant but whenyou think of

it, usually the toughestproblemto troubleshootis causedby the
smallest error. Thegreatest aid to solving a service problemis
information. Start gathering information from the boat operator
andwrite it on his job card or workticket. Find out pertinent facts,
such as:
o Whendid this trouble start?

o Howwas the boat loaded?
e Did the trouble occur suddenly, or start gradually?
Analyzethis informationandtry to matchit to similar situations

you have experiencedin the past. Keepin mind the fundamental
rules:
1. COMPRESSION
- Mixture inducted Into cylinder and compressed.
2. SPARK
- Properintensity at the propertime.
3. FUEL- Propermixture of air and fuel.
Theseare very old rules, but necessaryfor the engineto run. Use
these charts andthe service informationthey refer to. Donot try
to remember tolerances, settings, measurements, etc., as they
are written in the service manual.Leaveyour mindfree to analyze
the problem.
Followingis a list of the troubleshootingguides whichmaybe

found on the pagesindicated.
Title Page
1. Engine Will Not Crank .............................. 1-27

2. Engine Cranks, But Will Not Start .................... 1-27
3. Hard Starting - Cold Engine ......................... 1-28
4. Hard Starting - Hot Engine ......................... 1-28
5. Engine Runs Rough ............................... 1-29
6. Engine Noises and Vibrations ........................ 1-29
7. Engine Overheats ................................. 1-30
8. Engine Dies Out ................................... 1-31
9. Engine Won’t ReachOperating RPM.................. 1-31
10. Defective Engine Lubricating System................ 1-32
11. LowBattery Voltage After Short Storage .............. 1-32
1-2~ Engine/en9
Engine Will Not Crank
o - o
¯ Battery condition: weak, dead, sulfated, bad cells

e Battery cables for loose or corroded connections
o Shorted or open ignition switch
¯ Starter motor and solenoid for shorts, grounds or open
circuits
¯ Starter assist solenoid/starter relay
¯ Circuit breakers
® Wiring from battery to ignition switch
¯ See Electrical/ignition WorkshopManual
Engine Cranks, But Will Not Start
e Primary circuit wiring from ignition switch to ignition

coil/ignition module
e Secondarycircuit wiring from coil to spark plug
¯ Spark plugs for proper gap, fouling, burned electrodes,
cracked or dirty insulator
¯ See ElectricaUIgnition Workshop Manual
¯ EECpower lead attachment/relay/fuse/circuit breaker
¯ Ignition circuit breaker
¯ Low battery voltage
¯ Quantity and condition of fuel in boat tank

¯ Operation and flow capacity of boat anti-siphon valve
¯ Fuel tank vent is unrestricted
e Fuel tank pick-up screen is clean
¯ Correct diameter/unrestricted boat fuel lines
¯ Fuel shutoff and multiple tank valves
o Fuel pump/relay/circuit breaker operation
¯ Fuel filter canister and carburetor filter
o Carburetor accelerator pump
e See Fuel System WorkshopManual
.... II = II 0 ® II ..... =
® Conduct test following procedure in this section, and

compare readings to Compression Limit Chart
Hard Starting - Cold Engine
Ask these questions first:
¯ Carburetor choke operation and adjustment

® Fuel lines for obstructions
® For debris inside fuel tank
® See Fuel System Workshop Manual
o For clean external canister and carburetor fuel filters

¯ Empty carburetor float bowl due to evaporation
o Water in fuel due to condensation
o Fuel quality deterioration
o See Fuel System Workshop Manual
o Carburetor choke operation and adjustment

o Carburetor accelerator pump
o Fuel systemfor leaks, dirt, or obstructions
¯ Engine timing and ignition system
e See Electrical/Ignition and Fuel SystemWorkshopMan-
uals
Hard Starting - Hot Engine=--

Ask these questions first:
® Carburetor choke operation and adjustment

® See Fuel System Workshop Manual
o Brand, type or octane of fuet

o Spark plugs
e Water in fuel
o Condition of battery and cables
¯ Starter motor for overheat damage
o & D
D Q ~
® Ignition system primary circuit

¯ Ignition coil/ignition module
o Engine timing
o Carburetor choke operation and adjustment
e See Electrical/ignition and Fuel System WorkshopMan=
uals
1-28 E.gi.o/~g
Engine Runs Rough .....
’ 0 0 " " °E~ "
¯ Idle speed and idle mixture

¯ Engine timing and spark plugs
e Fuel pump pressure
e Water or contaminants in fuel
e Carburetor or manifold vacuum leak
® Internal carburetor fuel leak
¯ See Fuel System WorkshopManual
__; , _ °_:_’, .
¯ Air leak on suction side of fuel system

¯ Too low octane fuel
¯ Ignition system secondary circuit
¯ Engine timing
¯ Wrong model 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 section and ElectricaUIgnition
and Fuel System Workshop Manuals
Engine Noises and Vibrations ----
o Rapping only whenstarting (oil too heavy for prevailing

weather, varnish on lifter, oil needs to be changed)
e intermittent rapping (leakage at lifter checkball)
o Idle noise (excessive leak downrate, faulty check ball
seat)
o Generally noisy (excessive oil in crankcase, stuck lifter
plunger)
e Loud noise at operating temperature (scored lifter plung-
er, fast leak downrate, oil viscosity too light for prevail-
ing weather or operating temperatures)
¯ See appropriate Engine section
EngineNoisesand Vibrations, Cont.
¯ improper tuning
¯ incorrect spark plug wire routing
¯ Use higher octane fuel
¯ See Electrical/Ignition WorkshopManual
¯ Raw-water pump
® Loosebelts, pulleys
¯ See CoolingSystemsection
¯ Loose, broken or worn engine mounts

¯ Looselag screws holding mountsto stringer
¯ Loosebolt(s)
¯ Loosepulley, worn bearings

¯ Loose mounting bolts
e Failed U-joints or gimbal bearing

e Damaged internal drive unit components
¯ Worn, bent or broken propeller hub or blades
e Loose, worn or damagedengine coupler
EngineOverheats- Check:
¯ Actual enginetemperatureby verifying with an accurate
thermometer
¯ Gaugeoperation and wiring circuit
¯ Sendingunit operation and wiring circuit
¯ Raw-waterpump, circulating pumpand belts
¯ Waterintake screens for blockage
¯ Thermostat
¯ Water supply hoses
¯ Engine timing
e Water leaks on pressure side of raw-water pump
¯ Air leaks on suction side of raw-water pump
¯ Engine compression
1-30 E~i~g
Engine Dies Out
¯ Fuel gauge operation and wiring

¯ Fuel level in tank
¯ Water or debris in fuel
¯ Fuel pickup tube and screen blockage
¯ Fuel tank vent blockage
e Pluggedexternal canister or carburetor fuel filters
e Air leak on suction side of fuel system
e Fuel leak on pressure side of fuel system
¯ Inoperative, restricted or incorrectly sized anti-siphon
valve
¯ Boat fuel lines too small in diameter
¯ Fuel pump pressure and suction
¯ Carburetor cleanliness and operation
¯ See Fuel System WorkshopManual
~0k"F~ ,ql
¯ Primary and secondary ignition circuits

¯ ignition switch
¯ Circuit breakers
¯ Wiring between engine and dash
¯ Main engine harness wiring
¯ See Electrical/ignition Workshop Manual
e Drive unit for internal damage

e Oil pressure gauge and crankcase oil level
e 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, damagedblades, slipping
hub
¯ Crankcase oil volume
¯ Marine growth on hull and drive
¯ Wrongdrive unit gear ratio
¯ Operating at high altitude
¯ Restricted carburetor air intake
¯ Restricted exhaust outlets in engine, transom shield or
drive
¯ Poor cylinder compression
¯ Carburetor size and type correct for engine
e Fuel pump pressure and vacuum
e Boat overloaded, or load improperly placed
e Engine overheating
e Engine timing and ignition system operation
¯ Remotecontrol cables and linkage for proper attachment
and travel
E~i~.~ 1-31
Defective Engine Lubricating System _
® Cloggedor incorrect oiJ filter

® Worn oil pumpgears, cover or shaft
¯ Wornor collapsed oil pumprelief valve spring, or foreign
materiam caught on valve seat
® Oil pumprenief valve plunger loose in cover
® Damagedfilter bypass grommet
¯ Clogged oil pickup screen, broken tube or housing
® Plugged crankshaft or block oil galleys
¯ Dirty or defective hydraulic lifters, clogged push rod
passages
¯ Poor quality, incorrect viscosity or quantity of oil
¯ Incorrect hose routing on remote filter systems
® Water in crankcase oiU from condensation, defective head
gasket, oia cooler, or cracked manifold/block water pas-
sages
¯ Oil gauge/warning horn operation and wiring

® Engine temperature
o Oil pressure gauge and warning horn sender operation
and wiring
LowBattery Voltage After Short Storage
e AHelectrical accessories including ignition circuit off

o Disconnect main battery negative cable from battery
o 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 movementno matter how slight indicates draw
from battery
¯ Disconnect main engine harness 10-Pin Connector
1. Meter drops back to "0", problem caused by boat
system, continue to isolate each boat electrical acces-
sory untiB 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
e Repair or replace components as necessary
1-32 E~i°~t~
Tune=up
Specifications = -- _
Engine Firing Order

3.0 GS ......................................... 1-3-4-2
4.3 GL, GS, Gi .............................. 1-6-5-4-3-2
5.0 / 5.8 FL, Fi, FSi ....................... 1-3-7-2-6-5-4-8
5.7 GL, Gi ............................... 1-8-4-3-6-5-7-2
7.4 / 8.2 GL, Gi, GSi ..................... 1-8-4-3-6-5-7-2
Fuel PumpPressure
All Carbureted Models ................ 40-48kPa (5.75 - 7 psi)

All Fuel Injected .................. Low13,8-27,6 kPa (2-4 psi)
4.3, 5.7 Gi ...................... High 62,0-89,6 kPa (9-13 psi)
5.0, 5.8 Fi, FSi .................. High 214-269 kPa (31-39 psi)
7.4 Gi, GSi ..................... High 214-269 kPa (31-39 psi)
Formore
detailedinformation
onfuel injection~referto pertinent
Diagnostic
WorkshopManuals.
ForFi andFSimodels,see:
MFi Diagnostic WorkshopManual(5.0 Fi, 5.8 Fi/FSi) = Ford
For Gi andGSimodelssee:
TBI Diagnostic WorkshopManual (4.3, 5.7 Gi) -
MFi Diagnostic WorkshopManual (7.4, 8.2 Gi/GSi) -
Crankcase Capacities
Model Less Filter With Filter

3.0 GS 3.5qts. (3,3liters) 4.0qts. (3,8liters)
4.3 GL, GS,Gi 4.0qts. (3,8litres) 4.5qts. (4.3litres)
4.3 GL, GS,Gi 2 4.5qts. (4.3litres) 5.0qts. (4.7liters)
5.0 FL 5.0qts. (4,7litres) 6.0qts. (5,7litres)
5.7 GL, Gi 5.0 qts. (4,7 lives) 6.0qts. (5,7litres)
5°8 FL 5.0qts. (4,7litres) 6.0qts. (5,7litres)
5.0 Fi 5.0qts. (4,7litres) 6.0qts. (5,7litres)
5.8 Fi, FSi 4.0qts. (3,8litres) 5.0qts. (4,7litres)
7.4 GL 5.0qts. (4,7litres) 6.0qts. (5,7litres)
7.4 GL3 8.0qts. (7,6 litres) 9.0qts. (8,5litres)
7.4 8.2 Gi, GSi 8.0qts. (7,6 litres) 9.0qts. (8,5litres)
2 with ribbed aluminmoil pan
~ with 41/2 raw water pumppulley
Tune-upSpecifications
Idle* and Operating RPM
3.0 GS
Idle ...................................... 650-750 RPM
WOT.................................. 4200-4600 RPM
4.3 GL
Idle ...................................... 550-650 RPM
WOT .................................. 4200-4600 RPM
4.3 GS
Idle ...................................... 550-650 RPM
WOT .................................. 4400-4800 RPM
4.3 Gi
Idle ........................... 600 RPM- Not Adjustable
WOT.................................. 4400-4800 RPM
5.0 FL
Idle ...................................... 550-650 RPM
WOT.................................. 4200-4600 RPM
5.0 Fi
WOT.................................. 4200-4600 RPM
5.7 GL
Idle ...................................... 550-650 RPM
WOT.................................. 4200-4800 RPM
5.7 Gi
WOT.................................. 4200-4600 RPM
5.8 FL
idle ...................................... 550-650 RPM
WOT.................................. 4000-4400 RPM
5.8 Fi
WOT....................................... 4200-4600
5.8 FSi
WOT....................................... 4600-5000
7.4 GL
Idle ...................................... 550-650 RPM
WOT ....................................... 4200-4600
7.4 Gi
WOT ....................................... 4200-4600
7.4 GSi
WOT ....................................... 4800-5200
8.2 GL
Idle ...................................... 550-650 RPM
WOT .................................. 4400-4800 RPM
8.2 GSi
WOT................................. 4600 - 5000 RPM
* In Forward Gear
WOT= Wide Open Throttle
Tune-upSpecifications ~ r ¯
Distributor Specifications
:3.0 GS
Sensor Air Gap .......... N/A - De/co® EST ignition system
Distributor Rotation ........................... clockwise
4.3 GL, OS,Oi
Sensor Air Gap .......... N/A - DeJco®EST ignition system
5.0 FL
Sensor Air Gap .................... 0.008 inch (0,203 mm)
Distributor Rotation .................... counter-clockwise
5.0 Fi
Sensor Air Gap ......... N/A- Ford TFI-IV® ignition system
5.7 Gi
Sensor Air Gap .......... N/A - Delco® EST ignition system
5.8 FL
Distributor Rotation .................... counterclockwise
5.8 Fi, FSi
Sensor Air Gap ......... N/A - Ford TFI-IV® ignition system
5.7, 7.4", 8.2 GL
Distributor Rotation ............................ clockwise
7.4, 8.2 Gi, GSi
Sensor Air Gap .......... N/A - De~co®EST ignition system
Distributor Rotation ............................ clockwise
8.2 GL
SensorAir Gap .................... 0.008 inch (0,203 ram)
* Without Volvo Penta E.E.M. system. For information on Volvo Penta

E.E.M. see Electrical & Ignition WorkshopManual
P/N 7788887-3
Oil Pressure- All Models
800 RPM............................ 103-207 kPa (15-30 psi)j

2000 RPM ........................... 276-414 kP~L (40-60 ps~)j
Tune-up
Specifications
Spark Plugs
3.0 GS
Spark Ptug ................. VP-3851857-7, AC-MR43LTS,CH-RS12YC
Gap ............................................ 0.045" (1,143 mm)
Torque ............................................ 20 ft. lb. (27Nm)
4.3 GL, GS
Spark Plugs ................ VP-3851859-3, AC-MR43LTS,CH-RS12YC
Gap ............................................ 0.045" (1,143 mm)
Torque ............................................ 20 ft. lb. (27Nm)
4.3 Gi
Spark Plugs ................ VP-3851859-3, AC-MR43TS, CH-RV15YC4
Gap ............................................ 0.045" (1,143 ram)
Torque ............................................ 20 ft. lb. (27Nm)
*4.3 GL, GS, Gi
Spark PJugs ................ VP-3856756-0, AC-MR43LTS,CH-RS12YC
Gap ............................................ 0.045" (1,143 ram)
Torque ............................................ 20 ft. lb. (27Nm)
5.0 FL
Spark Plugs ................ VP-3851861-9, MC-ASF32C, CH-RV15YC4
Gap ............................................. 0.035"(0.889 mm)
Torque ..................................... 5-10 ft. tb. (6.7-13.5 Nm)
5.0 Fi
Spark Plugs ............... VP-3851857-7, MC-AWSF32C,CH-RS12YC
Gap .............................................. 0.045"(1.14 ram)
Torque ..................................... 5-10 ft. lb. (6.7-13.5 Nm)
5.7 GL
Spark Plugs ................. VP-3851859-3, AC-MR43T,CH-RV15YC4
Gap .............................................. 0.035" (0.89mm)
Torque ............................................ 20 ft. lb. (27Nm)
5.7 Gi
Spark Plugs ................. VP-385t862-1, AC-R43TS, CH-RV15YC4
Gap ............................................ 0.045" (1,143 ram)
Torque ............................................ 20 ft. lb. (27Nm)
5.8 FL
Spark Plugs ................ VP-3851861-9, MC-ASF32C, CH-RV15YC4
Gap ............................................ 0.035" (0,889 mm)
Torque ..................................... 5-10 ft. lb. (6.7-13.5 Nm)
5.8 Fi, FSi
Spark Plugs ................ VP-3851888-4, MC-AWSF22C,CH-RS9YC
Gap .............................................. 0.045"(1.14 mm)
Torque ..................................... 5-10 ft. lb. (6.7-13.5 Nm)
7.4 GL
Spark Plugs ................. VP-3851861-9, AC-MR43T, CH-RV15YC4
Gap ............................................ 0.045" (1,143 mm)
Torque ............................................ 20 ft. Jb. (27Nm)
7.4 Gi
Spark Plugs ................. VP-3851862-1, AC-R43TS, CH-RV15YC4
Gap ............................................ 0.045" (1,143 mm)
Torque ............................................ 20 ft. lb. (27Nm)
7.4 GSi
Spark Plugs ................. VP-3851861-9, AC-MR43T,CH-RV15YC4
Gap ............................................ 0.045" (1,143 mm)
Torque ............................................ 20 ft. lb. (27Nm)
8.2 GSi
Spark Plugs ................. VP-3851861-9, AC-MR43T, CH-RV15YC4
Gap ............................................ 0.045" (1,143 mm)
Torque ............................................ 20 ft. lb. (27Nm)
*With ribbed aluminumoil pan
VP = Volvo Penta CH = Champion
AC = AC Delco MC= Motorcraft
1-36 Engine/eng
Tune-up
Specifications
Timing and Fuel Requirements
3.0 GS ...................... 0° TDC- w/87 AKI or higher

Volvo Pema885163-6 shunt required
4.3 GL, GS.................. 0° TDC- w/89 AKI or higher

5° ATDC- w/87 AKI
Volvo Penta 885163-6shunt required
4.3GL, GS* . ............... °BTDC-w/89AKIorhigher

6
1 ° BTDC- w/87 AKI
Volvo Penta 885163-6shunt required
4.3 Gi ...................... 8° BTDC- w/87 AKI or higher

Service Moderequired
5.7 GL ..................... 8° BTDC- w/86 AKI or higher
5.7 Gi ...................... 8° BTDC- w/87 AKI or higher

5.0 FL .................... 10° BTDC- w/86 AKI or higher
5.8 FL .................... 10° BTDC- w/86 AKI or higher
5.0 Fi ....................... 5° BTDC- SPOUTremoved
5.8 Fi, FSi ................... 5° BTDC- SPOUTremoved
7.4 GL .................... 10° BTDC- w/89 AKI or higher

6° BTDCw/87 AKI or higher
7.4 GL w/E.E.M ............... 10° BTDC- Non Adjustable

w/86 AKI or higher
7.4 Gi ..................... 10° BTDC- w/87 AKI or higher

7.4 GSi ................... 10° BTDC- w/87 AKI or higher

8.2 GL ............. ~ ....... 8° BTDC- w/89 AKI or higher

3° BTDC- w/87 AKI or higher
8.2 GSi ................... 10° BTDC- w/87 AKI or higher

E.E.M. = Volvo Penta Electronic EngineManagement

*with ribbed, aluminum
oil pan
METRIC CONVERSIONCHART
inches X 25.4 = millimetres (ram) foot-pounds X 1.3558 = joules (j)

feet X 0°3O48 = metres {m) calories X 4.187 = joules {j)
yards X 0.9144 = metres (m) Btu X 1055 = joules {j)
miles X 1.6093 = kilometres (kin) watt-hours X 3500 = joules(j)
inches X 2.54 = centimetres (cm) kilowatt - hrs X 3.600 = megajoules(M J)
W | =|J:lib=It[el~[=]Fjlh’N-~
~I =It;L|J=lIKEe]
~[~’~JJ
Lv~l’ji
i [=]~|
=
inches X 645.16 = millimetres= =)
(ram miles/gal X 0.42514= kilometres/litre (km/I)
2
inches X 6.452 = centimetres= 2)
(cm
=
feet X 0.0929 = metres= =)
(m Note:
=
yards X 0.8361 = metres= (m
=) 235.2/(mi/gal) = litres/100
acres X 0.4047 = hectares (104 2) 235.2/(litres/100 km)= mi/gal
(ha)
zmiles X 2.590 = kilometres= =)
(kin
footcandles X 10.76 2 =)
= lumens/metre (Um/m
3
inches X 16387 = millimetres3 z)
(ram
3
inches X 16.387 = centimetres3 (cm
3)
3
inches X 0,01639 = litres (I) e Q= o
quarts X 0.94635 = litres (I)

gallons X 3.7854 = litres (I) inches HG(60°F) X 3.377 = kilopascals (kPa)
zfeet X 28.317 = litres (I) pounds/sqin X 6.895 = kilopasca|s (kPa)
~
feet X 0.02832 = metres3 3) (m inches HsO(60°F) X 0.2488 = kilopascals (kPa)
fluid oz X 29.57 = miliilitres (ml) bars X 100 = kilopascals (kPa)
3
yards X 0.7646 = metres3 3) (m pounds/sqft X 47,88 = pascals (Pa)
ounces
(av) X 28.35 = grams (g) horsepower X 0.746 = kilowatts (kW)
pounds(av) X 0.4536 = kilograms (kg) ft-lbf/min X 0.0226 = watts {W)
tons (2000Ib) X 907.18 = kilograms (kg)
tons (2000Ib) X 0.90718 = metric tons (t)
[FORCE
°Celsius = 0.556X (°F -32)
ounces
- f (av) X 0.278 = newtons (N) °Fahrenheit = (1.8 X °C) +32
pounds- f (av) X 4.448 = newtons (N)
kilograms- f X 9.807 = newtons (N)
pound-inches X 0.11299 = newton-metres (N.m)

2
feeUsec X 0,3048 = 2)
= metres/see (m/S pound-feet X 1.3558 = newton-metres (N-m)
2
inches/sec X 0.0254 = (m/S
= metres/sec 2)
miles/hour X 1.6093 = kiiometres/hour(kin/h)

feet/sec X 0.3048 = metres/sec(m/s)
kilometres/hr X 0.27778 = metres/sec(m/s)
miles/hour X 0.4470 = metres/sec(m/s)
1-38 Engine/eng
DR2949 Drill Size ConversionChart
SHOWINGMILLIMETERSIZES, FRACTIONALAND
DECIMALiNCH SIZES ANDNUMBERDRILL SIZES
Milli- 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 bet Meter Equiv. tional
.1 .0039 1.75 .0689 .... 1570 22 6.8 .2677 10.72 .4219 27/64
.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 7/re
.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 2%4
.... 0135 80 t.9 .0748 4.2 .1654 7.1 .2795 11.91 .4687 ls/32
.35 .0138 .... 0760 48 .... 1660 19 .... 2811 K 12.0 .4724
.... 0415 79 1.95 .0767 4.25 .1673 7.14 .2812 %2 .. . 12.30 .4843 sl/~
.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 11/~ 7.3 .2874 13.0 ,5118
.45 .0177 2.05 .0807 .... 1730 1’7" .... 2900 L 13.10 .5156 3~’64
.... 0180 77 .... 0810 46 4.4 .1732 7.4 .2913 13.49 .5312 17/32
.5 .0197 .... 0820 45 .... t770 16 .... 2950 M 13.5 ,5315
.... 0200 76 2.1 .0827 4.5 .1771 7.5 .2953 13.89 .5469 3%4
.... 0210 75 2.15 .0846 .... 1800 15 7.54 .2968 19/s4 ... 14.0 .5512
.55 .0217 .... 0860 44 4.6 .1811 7.6 .2992 14.29 3624 9Ae
.... 0225 74 2.2 .0866 .... 1820 14 ..... 3020 N 14.5 .5709
.6 .0236 2.25 .0855 4.7 .1850 13 7.7 .30311 14.68 .5781 3%4
.... 0240 73 .... 9890 43 4,75 .1870 7.75 .3051! 15.0 .5906
.... 0250 72 2.3 .0905 4.76 .1875 ~9 7.8 .3071, 15.08 .5937 W3z
.65 .0256 2,35 .0925 4.8 .1890 12 7.9 .3110 15.48 .6094 39/~
.... 0260 71 .... 0935 42 .... 1910 11 7.94 .3125 ~16 ,.. 15.5 .6102
.... 0280 70 2.38 .0937 ~2 ... 4.9 .1929 8.0 .3150 15.88 .6250 9h
.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/e4
.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 .324~| 17.0 .6693
.8 .0315 .... 0995 39 .... 2010 7 8.3 .3268 17,06 ,6719 4%4
.... 0320 67 .... 1015 38 5.16 .2031 1~4 9i 8.33 .3281 21/r~ . .. 17.46 ,6875 11/lS
.... 0330 66 2.6 .1024 .... 2040 6 8.4 .3307 17.5 3890
.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 =%2
.... 0360 64 2.75 .1082 5.3 .2086 .... 3390 R 18.5 .7283
.... 0370 63 2.78 .1094 %4 ....... 2090 4 8.7 .3425 18.65 .7344 47/~
.95 .0374 .... 1100 35 5.4 .2126 8.73 .3437 "~. .. . 19.0 ,7480
.... 0380 62 2.8 .1102 ..... 2130 3 8.75 .3445 19.05 .7500 3/4
.... 0390 61 .... II10 34 5.5 .2165 8.8 .3465 19.45 .7656 4%4
1.0 .0394 .... 1130 33 5.56 .2187 7,~z .. . .... 3480 S 19.5 .7677
.... 0400 60 2.9 .1141 5.6 .2205 8.9 .3504 19,84 ,7812 2%z
.... 0410 59 .... 1160 32 .... 2210 2 9.0 .3543 20.0 .7874
.05 .0413 3.0 .1181 5,7 .2244 .... 3580 T 20.24 .7969 sl/~
.... 0420 58 .... t200 31 5.75 .2263 9,1 .3583 20.5 .8071
.... 0430 57 3.1 .1220 .... 2280 1 9.13 .3594 23/64 ... 20.64 .8125 13/le
1.1 .0433 3.18 .1250 ~ ... 5.8 .2283 9,2 .362;! 21.0 .8268
1.15 .0452 3.2 .1260 5.9 .2323 9.25.36411 21.04 .8218 5~
.... 0465 56 3.25 .1279 .... 2340 A 9.3 .36611 21.43 .8437 27/.~
1.19 .0469 ¥64 ... .... 1285 30 5.95 .2344 lS/~ ... .... 3680 U 21,5 3465
1.2 .0472 3.3 .1299 6.0 .2362 9.4 .37011 21,83 .8594 5%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 3/9 . .. 22.23 .8750 7/9
.... 0520 55 3.5 .1378 .... 2420 C .... 3770 V 22.5 .8858
1.35 .0513 .... 1405 28 6.2 .2441 9.6 .3780 22.82 .8906 sT/e4
.... 0550 54 3.57 .1406 %4 ... 6.25 .2460 D 9.7 .3819 23.0 .9055
1.4 .0551 3.6 .1417 6.3 .2480 9.75 .3838 23.02 .9062 2%2
.45 .0570 .... 1440 27 6.35 .2500i/,= E 9.8 .3858 23.42 .9219 s%4
1.5 .0591 3.7 .1457 6.4 .2520 .... 3860 W 23.5 .9252
.... 0595 53 .... 1470 26 6.5 .2559 9.9 ,.3839 23.81 .9375 15/16
.55 .0610 3.75 .1476 .... 2570 F 9.92 .3906 2%4 .. . 24,0 .9449
.59 .0625 ¼6 ... .... 1495 25 6.6 .2598 10.0 .3937 24.21 .9531 9V~
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 zl/32
1.65 .0649 3.9 .1535 6.75 .2657 1%4 ... 10.32 .4062 1¥32 .. . 25,0 .9843
.7 .0669 .... 1540 23 6.75 .2657 .... 413(I Z 25.03 .9844 93/94
.... 0670 51 3.97 .1562 ~ .,. .... 2660 H 10.5 .4134 25.4 1.0000 1
DR2949-ENG
SYMBOLS
Certain symbolsor combinations of symbolsmayappear on your Volvo Penta stern drive or on its
accessories, it is very important that you understandtheir meaningor purpose,ff any symbolis not
clearly understood,see your DeaJer.
"Safety Warning" Symbols
Fire hazard
Contents under pressure
"Position indicator" Symbols
Shift positions
NEUTRAL
RAISE LOWER im®.~
FORWARD REVERSE
"Condition" Symbols
Hour meter
¯ Voltmeter
¯ Ammeter G Tachometer
Voltmeter Fuelfilter
Oil filter
Watertern peratu re Emergency stop ’~Oil pressure
"instructional" Symbols
¯ Use gasoline
¯ Gasoline is present ~ Read Operator’s Manual
before operating product Oilfill
DR3847
Englne/eng ’i -40
Lubrication and Inspection Chart
items marked~ Safety Warningare safety related service points to prevent mechanicalfailures, fire
and explosion. Makesure the safety related service is pertFormedat these points and at the intervals
specified.
Service Point 20-Hour Check Every 100 Hours Recommendations

or as Specified
Alternator Belt, Check and tighten Checkbelt for ten~,ion and Adjust tension to specifications.
Powor Steering PumpBelt deterioration. Replacedeteriorated belt. Keepspare
on board.
Checkfor damageto grill Seasonallyclean end inspect. If damaged,replace with specified

Flame Arrestor area. Must be firmly Damaged unit may allow backfire VolvoPentaparts. If dirty, clean in
attached, flame to enter engine compartment, solvent, end air dry before
installation.
Drain and refill ew~ry100 hours or

Crankcase Checkoil level dally, once a season, whichever comes Seespecifications.
first.
Engine Alignment Check Seasonally Check engine alignment.
Oil Filter Replace Replace Seespecifications.

or as Specified
Power Steering Pump Checkreservoir fluid level Checkreservoir flLiid ]eve[. Use Vo/vo Penta powertrim/tilt &
steering fluid.
Steering Cable Ram Checkand lubricate Lubricate every 50 hours or every 60 Use Volvo Penta Grease.
days, whichevercomesfirst.

Lubrication and inspection Chart - Continued
Service Point 20J-lout Check Every 100 Hours Recomme~latfen$

or aa SpeciRed
Checkfor leaks. Check Seasonally check for hose Drain after operation in freezing
Engine belts for correct tension. deterioration. Volvo Penta SX, check temperatures, or during seasorml lay
raw-water pumpoperation. Repair up. Tighten connections. Re|01ace
as required. raw-water pumpimpeller every 2
years.
Seasonally check for hose Drain after operation in freezing

TransomShield deterioretiono temperatures, or during seasonal lay
up.
Check water pickup Reptecegear oil avery 100 hours or Drain after operation in freezing
Drive Unit screensfor obstructions. ORC6 a season. temperatures, or during seasonallay
Replaceoil. up.

or as Specified
Control Linkage Check operation. Check Adjust as required. Use Volvo Penta
adjustmentand lubricate. Grease.
Checkfor smoothshifting Seasonelly or every 100 hours,

in and out of forward and checkcable and shift assist for Replaceshift cable if necessary.
Shift Systsm reverse gears, proper operation.

or aa Specified
Checkfor fuel fumesand Repair or replace defective

Bilge Area leaks, components.
Hull Check for marine growth. Clean boat bottom.
Preparation for See Preparation for Boat6ng.

Boating Season
Check remote control and All boat safety equipmentshould be Be sure you have U.S.CoG.required
Safety Equipment emergencystop switch, if checkedfor condition and proper equipment aboard (check Coaat Guard
equipped, for proper operation, regulations)o
operation.
Storage See Off-Season Storage.
Trailer Secsonslly repack wheel bearings. Use Wheel Beadng Grease.

Section 2
3.0 GS
Volvo Penta Engine
Table of Contents
Camshaft .......................... 2-14 High.Rise Exhaust Elbow Replacement... 2-37

Camshaft Bearings .................. 2-16 Hydraulic Valve Lifter ................. 2-4
Circulating Pump .................... 2-32 Intake/Exhaust Manifold .............. 2-3
Connecting Rod Bearings ............. 2-19 Oil Filter By-Pass Valve ............... 2-35
Crankshaft ......................... 2-18 Oil Pan Replacement ................. 2-32
Crankshaft Bearings ................. 2-20 Oil Pump .......................... 2-33
Cylinder Block ...................... 2-27 Oil Seal, Rear Main Bearing Replacement 2-23
Cylinder Head Assembly .............. 2-6 Oil Seal Retainer Replacement ......... 2-23
Distributor Lower Bearing ............. 2-31 Piston Rings ........................ 2-25
Engine Coupler Replacement ........... 2-40 Pisten and Connecting Rod ............ 2-23
Engine Specifications ................. 2-42 Timi~g Gear Cover ................... 2-12
Exhaust (Flapper) Valve Replacement .... 2-39 Torque Specifications ................. 2-45
Exhaust Hose Replacement ............ 2-38 Valve Lash Adjustment ............... 2-5
Front Engine Mount .................. 2-35 Va|ve Spring and Seal Repair ........... 2-6
Height Adjustment ................. 2-37
Before removing cooling system hoses, it may be neces-

sary to removeboat from water to prevent flooding boat.
Safety Warnings
Before working on any part of the engine, read the section called
Safety at the end of this manual.
Unless instructed otherwise, always disconnect the battery

cables from the battery before workin!;] on electrical system to
prevent possible sparks or arcing in the engine compartment.
Before starting engine after repair or maintenance procedures,

always make sure engine compartment is free of fue~ vapors to
prevent possible fire and explosion.
Whenworking on an engine that is running or being cranked, use

extreme care to avoid getting hands, fingers or clothing caught
in the alternator, power steering, raw-water pumparid circulat-
ing pumpbelts, pulleys and other moving parts.
Genera/Motors Tools
item Part
Number
Air Line Adaptor .............................. J-23590

Bolt Guide Set .............................. J-6305-01
Cam Lobe Lift Indicator .......................... J-8520
Camshaft Bearing Remover and Installer .......... J-6098-01
Carbon Remover Brush .......................... J-808g
Crankshaft Gear Installer ......................... J-5590
Cylinder Bore Checker ........................... J-8087
Distributor Bearing Installer ....................... J-9535
Distributor Bearing Remover ................... J-9534-01
Piston Pin Tool ................................ J-24086
Piston Ring Tool ............................... J-8037
Rear Crankshaft Seal Installer .................... J-35621
Rocker Arm Stud Hole Reamer(0.003 Oversize) ....... J-5715
Rocker Arm Stud Hole Reamer(0.013 Oversize) ....... J-6036
Rocker Arm Stud Installer ........................ J-6880
Rocker Arm Stu6 Remover ..................... J-5802-01
Timing Cover Tool ............................. J-23042
Valve Guide Cleaner ............................ J-8101
Valve Guide Reamer Set ....................... J-5830-02
Valve Seal Tester .............................. J-23994
Valve Spring Compressor ........................ J-5892
’Valve Spring Tester ............................. J-8056
Vibration Damperand Crankshaft Gear Remover ..... J-6978-E
Order Directly from:
Kent-Moore Tool Division

28635 Mound Road
Warren, MI 48092
800-345-2233
Price and ordering information are available from Kent-Moore

Tool Division.
Material Required
Molykote Lubricant
Gasket Sealing Compound
Permatex No. 2
GMSuper Engine Oil Supplement
Plastigage (Green)
DuraPlus Synthetic Motor Oil or Equivalent
For additional service information not covered in this manual,

obtain the appropriate Chevrolet Engine WorkshopManual from:
Helm Inc.
P. O. Box 07130
Detroit, MI 48207
2-2 Engineleng
Intake/Exhaust Manifold
RemovaJ
,~ 1. Disconnect battery cables at battery. Removethrottle

,cable from anchorblock and actuating bracket.
2. Drain water from block and exhaust manifold (see C~)oling

System Section in this manual).
3. Removecarburetor from intake manifold. Follow the instruc-

tions in Fuel SystemsWorkshopManual. 34734
I~] 4. Disconnect water hoses (~) and ® running between

manifold end cap and thermostat housing, and thermostal; hous-
ing and power steering cooler or transom shield.
5. Power Steering Models: Removealternator ©, and oil

,cooler and mountingplate (~}).
[~ 6. Loosen upper hose clamps ~) securing exhaust hose to

high rise elbow. Loosen and remove screws and lock wasl~ers ®
securing elbow to manifold and removethe throttle linkage plate
and elbow. 22479
7. Remove four bolts, two nuts and lock washers securing

manifold to cylinder head, then pull manifold off of head. Discard
gasket.
8. Clean all gasket surfaces of cylinder head and manifold and

check for cracks on the manifold casting.
Installation
1. Position a newgasket over the manifold studs on the head. Use

a gasket sealer if leakage has occurred. Carefully install the
manifold in position making sure that the gasket is correctly 34727
placed.
2. install nuts, bolts and washers while holding the manifold in

place. Tighten bolts and nuts finger tight, then alternately 1lighten
to 20-25 ft. Ibs. (27-34 N-m) working from the center towards the
ends.
3. Apply gasket sealer to a new elbow gasket and place it on the

manifold. Push the elbow into the exhaust hose, then install the
elbow, throttle linkage plate, lock washers, and screws. Tighten
the screws to 12-14 ft. Ibs. (16-19 N-m).
[~ 4. Install carburetor using a new mounting gasket following
the instructions in Fuel SystemsWorkshop Manual. Install water
hoses from thermostat housing to manifold ~), and transom
shield or power steering cooler to thermostat ®.
5. Power steering models: InstalU alternator, oil cooJer and
mounting plate.
6. Reconnect throttle cable to anchor block and actuating

bracket. Securewith cotter pin.
Z~ 7. Connectbattery cables. Start engine and check for fuel

leaks.
HydraulicValveLifter
1. With air hose and cloths, clean dirt from cylinder head and
adjacent parts to avoid getting dirt into engine, it is extremely
important’that no dirt gets into the valve lifters.
2. Disconnect ventilation hose, fuel line, and fueJ pumpoverflow

hose. Removecircuit breaker bracket. Removerocker arm cover.
3. Loosen rocker arm nuts and pivot the rocker arms free of the
push rods.
4. Disconnect spark plug wires at plugs. Removehigh tension mead 22477

from coil. Removeboth connectors from coil. Removecoil and
mounting bracket from cylinder head.
El: 5. Removeboth connectors at distributor. Take off cap, note
distributor rotor position and removedistributor. (Mark distribu-
tor housing and block with chalk at point of rotor.)
8. Removepush rod cover and gasket. ROTA33NG

- NORMAL,
OK- NOTROTATING
7. Remove push rods and lift out valve lifters that require service.
Place lifters in a woodenblock having numbered holes, or use
other suitable meansof identifying them according to original
position in the engine.
8. If less than a complete set of lifters is being removed,immedi-

ately disassemble and inspect one or two for presence of dirt or
varnish. If Hfters contain dirt or varnish, it is advisable to replace
all lifters. Otherwise, it will be satisfactory to service only those
lifters that are not operating properly. LLED - SHOULD
BE REPLACED
- SOFT, WORN
[~ 9. Examine the cam contact surface at lower end of lifter

body. if this surface is excessively worn, galmed or otherwise
damaged,discard the lifter assembly, in this case, also examine
the mating camshaft lobe for excessive wear or damage.

Insta||ation
1~ Before installing any new lifters, coat the bottom of each

lifter with Molykoteor its equivalent.
1. install valve lifters in cylinder block. If anynewlifters or a new

camshaft has been installed, an additive containing EP lubricant
such as GM Engine Oil Supplement must be added to the
crankcaseoil for break-in.
2. install pushrods onto lifters and install push rod cover with a
new gasket.
:3. install distributor (position rotor to markon housingand block).

LnstaHcoil and bracket. Connectboth connectors to coil. Install
distributor cap and attach spark plug and coil wires. Connectboth
connectors to distributor.
4. Install shift bracket assembly.
5. Pivot rocker arms in place and turn adjusting nuts the amount
necessary to eliminate lash.
Valve Lash Adjustment

Adjust valve lash whenlifter is on base circle of camas follows:
1. Remove distributor cap and crank engine until distributor rotor

points to numberone cylinder terminal, in this position the piston
in number one cylinder is at top dead center on compression
stroke. Both lifters are on base circle of camand both valves can
be adjusted.
i~] 2. Turn adjusting nut until all lash is removedfrom valve

train. This can be determined by checking push rod side play by
hand while turning nut slowly. At this point, turn adjusting nut
one moreturn to place the lifter plunger in center of its travel.
3. Follow steps 1 and 2 for each cylinder following firing order

sequenceand adjust remaining valve one cylinder at a time. No
further adjustment is necessary.
!~ Do not attempt to turn the adjusting nut one full turn while
the engine is operating. Adjustment in this mannerwill no1: allow
1:he lifters to bleed down.This would result in vanvetrain damage,
probably bent push rods. For those whoprefer to adjust thE; valve
lash while the engine is running, the preferred methodwould be
to find the "zero lash" point as described above and then slowly
turn the adjusting nut I/~ turn. Wait for the lifter to bleed down
(,several engine revolutions) and again turn adjusting nut 1/4 turn.
Continue this adjust-and-wait cycle until nut is one complete turn
down from "zero Jash" point. Repeat sequence on remaining
valves.
Engine/eng 2-5
4. Install rocker cover gasketandcover. Connectfuel line andfue~
pumpoverflow hose to carburetor.
5. Install circuit breakerbracket. Connectcrankcaseventilation
hose.
A
6. Startengineandcheckfor oil andfuel leaks,listen for lifter

noise. Checkenginetiming.
ValveSpringandSeal Repair
Refer to 4.3, 5.7 EngineSection for procedure.
Cylinder HeadAssembly
Thecondition of the cyminderheadand valve mechanism signifi-
cantly determines the power, performance and economyof the
overheadvalve engine. Extremecare should be exercised when
conditioning the cylinder headand valves. Maintain correct valve
stemto guideclearance,correctly grind valves andvalve seats, and
properlyadjust valves.
Removal
1. Removeintake and exhaustmanifold as describedunder heading
Intake/ExhaustManifold.
2. Disconnect coolant hoses at thermostat housing. Disconnect
spark plug wires and removespark plugs.
3. Disconnectfuel line retaining clips at thermostathousingand
cylinder head. Disconnectwire harnessfrom temperaturesending
unit, leaving harnessclear of clips on rocker armcover. Remove
thermostat housingassemblyfrom front of cylinder head. Discon-
nect fuel line at the fuel pumpand remove.
4. Removethe rocker armcover. Next, loosen the rocker armnuts
andpivot the rocker armsclear of the pushrods. Remove the push
rods.
5. Remove
the ignition coil andbracket. 860602
6. Remove the cylinder headbolts, cylinder head,andgasket. Place

the cylinder headon suitable holding fixture to prevent damageto
the head’s mating surface.
Disassembly
~1. Removerocker arm nuts, ball seats and rocker arms. Use
tool J-8062, compressthe valve springs and removevalve springs
caps, springs, oil seals, springs and spring dampers.Releasethe
spring compressortool and removekeys.
//~ Safety Related 2-6 E~ine/eng

’)_. Remove valves from bottom of cylinder head and place them in
a rack in their proper sequenceso they can be assembledin their
original positions.
CJeaning
[3 1. Clean all carbon from combustion chambers and valve

ports using tool J-8089. Inspect the cylinder head for cracks in the
exhaust ports, combustion chambers, or external cracks to the
water chamber. Clean carbon deposits from head gasket mating
surfaces.
[3~ 2. Thoroughly clean the valve guides using tool J-8101.
Clean all carbon and sludge from push rods and rocker arms.
:3. Clean valve stems and heads on a buffing wheel. Inspect the
valve for burned head, cracked faces or damagedstems.
4. Washall parts in cleaning solvent and dry them thoroughly.

Checkfit of vanve stems in their respective bores.
4L~ 5. Measure vamve stem clearance as follows: Clamp a dial

indicator on one side of the cylinder head rocker arm cover !gasket
rail, locating the indicator so that movementof the valw~ stem
from side to side (crosswise to the head} will cause a direct
movementof the indicator stem. The indicator stem must contact
the side of the valve stem just above the valve guide. With the
valve head droppedabout IA6 in. off the valve seat; movethe stem
of the valve from side to side using light pressure to obtain a
clearance reading, if clearance exceedsspecifications it will be
necessary to ream valve guides for oversize valves as outlined.
[~ Excessive valve stem to bore clearance will cause lack of

power, oil consumption, rough idling and noisy valves, an,d may
cause valve breakage. Insufficient clearance will result in noisy
and sticky functioning of the valves and disturb engine smooth-
ness of operation. Intake and exhaust valve stem to bore clear-
ance should be 0.001-0.0027 in. (0,025-0,007 mm). By using
micrometer and a suitable hole gauge, check the diameter of the
valve stem in three places; top, center and bottom. Insert hole
gauge in valve guide bore, measuring at the center. Subtract
highest reading of valve stem diameter from valve guide bore
(’enter diameter to obtain vaJve to valve guide clearance. If
clearance is not within limits use next oversize valve and ream
bore to fit using suitable reamer.
6. Checkvalve spring tension with tool J-8056 spring ’tester.

[N~--~ Onall models, springs should be compressedto 121hzin. at
860005
which height it should check 78-86 pounds (35,5-39,0 kg). Weak
springs affect power and economy and should be replaced if
below 70 pounds. (31,8 kg)
2-7 860006
Engineleng
8. Checkvalve lifters for free fit in block. Theend that contacts the
camshaft should be smooth. If this surface is worn or rough, the
lifter should be replaced, if lifter is damaged,check the corre-
sponding camshaft lobe for damage.
Repair
[~] 1. Valve Guide Bore:
Valves with oversize stems are available for inlet and exhaust
valves in the following sizes: 0.0003 in., 0.015 in., and 0.030 in.
Use the 11/32 in. diameter reamer sizes from reamer tool set
J-5830-02 which are: J-4822 standard; J-5830-1, 0.003 in oversize,
J-5830-2, 0.015 in. oversize and J-5830-3, 0.030 in. oversize to
ream the bores for the new vamves.
2. Rocker Arm Studs
Rocker arm studs that have damagedthreads may be replaced

with standard studs, if the studs are loose in the head, oversize
studs (available in .003 in. or .013 in. oversize) maybe installed
after reaming the holes as follows: 860007
Do not attempt to install oversize stud without reaming

stud hole.
Removeold stud by placing tool J-5802-01 over the stud.
Install nut and flat washer, and removestud by turning
nut.
b. Reamhole for oversize stud. Use tool J-5715 for 0.003 in.
oversize and toon J-8036 for 0.013 in. oversize.
[~ C. Coat press-fit area of stud with a hypoid axle lubricant.
Install new stud using tool J-8880. Tool should bottom
on head.
3. Valve Seats:
Reconditioning the valve seats is very important, because the

seating of the valve must be perfect for the engine to deliver the
power and performance built into it.
Another important factor is the cooling of the valve heads. Good

contact between each valve and its seat in the head is imperative 860008
to ensure that the heat in the valve head will be properly carried
away.
Several different types of equipment are available for reseating

valve seats; the recommendations of the manufacturer of the
equipment being used should be carefully followed to attain
proper results.
860009
2-8
Engme/eng
Regardless of what type of equipment is used, however, it is
essential that valve guides be free from carbon or dirt to ensure
proper centering of pilot in the guide.
a. lnstali expanding pilot in the valve guide bore and

expandpilot by tightening nut on top of pilot.
b® Place roughing stone o,r forming stone over pilot and just
clean up the valve seat. Usea 46° stone for both the inlet
and exhaust valve seats.
c. Removeroughing stone or forming stone from pilot, 860010

install finishing stone on pilot and cut just enoughmetal
from the seat to provide a smooth finish.
d. Narrow down the valve seats to the proper width for the
intake and exhaust. See Engine Specifications.
°This operation is done by grinding the port side with a 30
stone to lower seat and a 60° stone to raise seat.
e. Removeexpanding pilot and clean cylinder head care-

fully to remove all chips and grindings from above
operations.
E5--.] ~ Valve seats should be concentric to within 0.002 in.

total indicator reading.
4. Valves:
Valves that are pitted can be refaced to the proper angle, ensuring
correct relation between the head and stem on a valve refacing
machine. Vatve stems which show excessive wear, or valves that
are warped excessively should be replaced. Whena valve head 860011
which is warped excessively is refaced, a knife edge will be
ground on part or all of the valve head due to the amountof metal
that must be removedto completely reface. Knife edges lead to
breakage, burning or pre-ignition due to heat localizing on this
knife edge. if the edge of the valve headis less than %2in. thick
after grinding, replace the valve.
a® ff necessary, dress the valve refacing machine grinding

°wheelto makesure it is smoothand true. Set chuckat 45
mark for grinding valves.
b. Clampthe valve stem in the chuck of the machine.
c. Start the grinder and move the valve head out in line
with the grinder wheel by moving the lever to the left.
d, Turn the feed screw until the valve head just contacts
wheel. Movevalve back and forth across the wheel and
regulate the feed screw to provide light valve contact.
Engine/eng 2=9
e. Continuegrinding until the valve face is true andsmooth
all aroundvalve. If this makesthe valve thin the valve
mustbe replaced as the valve will overheat and burn. @
f. Remove valve from chuck and place stemin "V’" block.
Feedvalve squarely against grinding wheel to grind any
pit from rocker armend of stem.
Only the extreme end of the valve stern is hardenedto
resist wear. Donot grind end of stemexcessively.
goAfter cleaning valve face andcylinder headvalve seat of

©
grinding particles, makepencil marksabout1/4 in. apart
across the valve face, place the valve in cylinder head
and give the valve one-half turn in eachdirection while
exerting firm pressureon face of valve.
h. Remove valve andcheckface carefully, if all pencil marks
have not beenremovedat the point of contact with the
valve seat, it will be necessaryto repeat the refacing
operation and again recheckfor proper seating.
i. Grind and check remaining valves in the samemanner.

860013
Assembly
1. Starting with numberone cylinder, place the exhaust
valve in the port, and place the valve spring (~ and cap ~)
position. Placespring andcap on exhaustvalves. Then,using tool
J-8062, compressthe spring and install the oil seal © and valve
keys(~. Seethat the seal is fiat andnot twisted in the valve stem
grooveand that the keys seat properly in the valve stemgroove.
Place valve springs in position with the closed coil end

toward the cylinder head.
2. Assemblethe remainingvalve, valve springs, spring caps, oil 860614

seals andvalve keys in the cyJinder headusing tool J-8062.Check
seals by placing a vacuumcup over valve stem and cap, squeeze
vacuum cup to makesure no oil leaks past oil seal.
3. Checkthe installed height of the valve springs using a

narrow, thin scale to measurefrom the top of the shim or spring
seat in the head,to the top of the valve spring shield, if this is
found in excessof 12%zin., install a valve spring seat shim,
approximately 1/1s in. thick. At no time should the spring be
shimmed to give an installed height of less than 1%~zinch.
ff springs are to be changedwith cylinder headinstalled, 860015
refer to Valve Springand Seal Repair, in 4.3 and5.7 GLEngine
Section.
2-’1 0 Engine/eng
installation
1. The gasket surfaces of both the head and the block must be REAR
(:lean and free of any foreign matter, and free of nicks or heavy
scratches.
2. Cylinder head bolt threads in the block must be cleaned as well

as the threads on the cylinder head bolts. Dirt will affect bolt
torque.
[3~ 3. Place a new cylinder head gasket in position over the
dowel pins in the cylinder block. On engines with a steel gasket
coat both sides of a new gasket with a thin, even coat of Gasket
Sealing Compound.Too much sealer will hold the beads of the
gasket away from the block or head.
[~ The 3.0 Liter engine has a special marine head gasket. Do

riot substitute an automotive head gasket.
[4~ 4. Carefully guide cylinder head into place over dowel pins
and gasket. Coat threads of cylinder head bolts with Perma,texor
its equivalent. Install the bolts and run them downto the block.
L~ 5. Tighten the cylinder head bolts, with a torque wrench, in

three progressive steps following the sequenceshown.
Step 1 - 35 ft. robs. (47 N-m)

Step 2 - 65 ft. Ibs. (88 N-m)
Step 3 - 95 ft. Ibs. (129 N.m}
El. mnstalJ valve push rods downthrough openings in the cylinder

head and seat them in lifter sockets.
[E] 7. Install rocker arms, balls and nuts and tighten rocker arm
nuts until all pushrod play is taken up. 8 7
8. InstalU thermostat housing using a new gasket. Attach coolant
hoses. FRONT
860016
9. Clean all spark plugs with abrasive-type cleaner, inspect for

damage(replace if necessary) and set the gap at 0.045 in. (1,14
ram) using a wire gauge. Install the spark plugs. Tighten spark
pmugsto 20 ft. Ibs. (27 N-m).
10. instal{ coil and connect both connectors to coil. Connectwire

to temperature sending unit.
11. Clean manifold gasket surfaces and install new gasket over
manifold studs. Position manifomdand slide it into place over the
studs, making sure it seats against the gasket. Install bolts and
:nuts and tighten as described under heading |ntake/Exhaust
Manifold.
_zJ
860017
12. Adjust valve aash as outlined under heading Valve Lash
Adjustment. install rocker arm cover and gasket. Tighten screws
to 65 in. Ibs. (7,3 N-m).
13. Connectthrottle linkage and adjust.
14. Connectfuel line and overflow hose to carburetor and install

fuel line support clamps (two). Clean and install flame arrestor.
15. Start engine and check for fuel, coolant, and exhaust
leaks.
Timing Gear Cover
Removal
1. Drain coolant from block and exhaust manifold.
Z~ 2. Securely support engine and removefront engine mount.
3. Removealternator and power steering belts. Next remove

harmonic balancer and pulley assembly from pulley hub.
[~ 4. install puller tool J-6978-E to pulley hub with three %-24× 860019
2 in. bolts and removehub. Removepuller toon.
5. Removecirculating pumppulley.
6. Removecrankcase oil drain tube cap and withdraw oil with a

suction pump. Disconnect oil drain tube and removeoil pan.
7. Removetiming gear cover attaching screws. Removecover and

gasket.
Oil Seal Replacement
1. After removingtiming gear cover, pry oil sea[ out of cover from
front with a large screwdriver.
2. lnstaHI newlip seaJwith lip (openside of seal) facing inside

of cover, and drive or press seal into place with tool J-23042.
Oil Nozzle Replacement 860020
~] Removeold nozzle with pliers. Drive new nozzle in place

using a suitable light plastic or rubber hammer.
860021
Z~ Safety Related 2-12 Engme/eng
Timing Gear Cover mnstailation
1. Clean gasket surface on block and cover.
2. Install centering tool J-23042over end of crankshaft.
,3. Coat both sides of a newgasket with a light grease, and stick
gasket in position on block.
[~ 4. Pmacecover over centering tool and install cover screws.

Tighten screws to 80 in. Ibs. (9 N.m) and removecentering tool.
860022
5. Install oil pan using newgaskets. Tighten I/4-20 inch screws to
80 in. Ibs. (9 N-m). Tighten ~s-18 inch screws to 165 in Ibs. (18,6
N-m).
6. Connectoil drain tube to oil pan.
HarmonicBalancer Installation
[5--7 EEl 1. Coat oil seal contact area on harmonic balancer with
engine oil. Position hub over crankshaft and key, and start hub
into position with a mallet. Using tool J-55g0, drive hub onto
crankshaft until it bottoms against crankshaft gear.
Crankshaft extends slightly through huband a hollow toom

is necessary to drive hub completely into bottomed position.
2. Thereare two 3/s in. holes and one s/le in. hole that must
be matched on hub in order to properly position timing mark.
3. Install circulating pumppulley.
4. instalm alternator and power steering belts and adjust to

specifications.
5. Install front engine mount. 860023
6. Fill engine crankcase with proper amountof oil.
7. Lake or tank test unit and check for leaks. \
860024
Eng~ne/eng 2-13
Camshaft
Measuring CamshaftLift
Removeboth connectors from ignition coil.
If improper valve operation is indicated, measurethe lift of each

push rod in consecutive order and record the readings.
1. Removevalve cover and rocker arms.
[~ 2. Position indicator with ball socket adapter (Tool J-8520)

push rod.
3. Rotate crankshaft slowly in the direction of rotation until the

lifter is on the heel of the camlobe. At this point, the pushrod will
be in its lowest position.
4. Set dial indicator on zero. Rotate the crankshaft slowly, or

attach an auxiliary starter switch and "bump" the engine over,
until the pushrod is in the fully raised position.
5. Comparethe total lift recorded from the dial indicator with

specifications. The correct lift is 0.253 inch _+ 0.005 inch (8,426 +
o0,127 ram).
6. Continueto rotate the crankshaft until the indicator reads zero.

This will be a check on the accuracy of the original indicator
reading. 860026
7. if camshaft readings for all lobes are within specifications,

removedial indicator assembly. Install and adjust valve mecha-
nism.
Remova|
1. Withdraw oil from crankcase. Drain coolant from block and

exhaust manifold.
2. Removevalve cover and gasket. Loosen valve rocker arm nuts

and pivot rocker arms clear of push rods.
3. After noting position of rotor, removedistributor.
4. Removecoil, side cover, and gasket. Removepush rods and

valvelifters.
5. Removecrankshaft pulley and hub. Disconnect oil drain tube.

Removeoil pan and timing gear cover.
EE] 6. Removetwo camshaft thrust plate screws by working

through holes in camshaft gear.
860027
2-14 Engine/eng
7. Removethe camshaft and gear assemblyby pulling it out
throughthe front of the block.
Support shaft carefully when removing so as not to

damagecamshaft bearings.
Inspection
The camshaft has three bearings, all with the samejournal

diameterof 1.8692in. to 1.8682in. (4,7478to 4,7452cm). ’These
dimensionsshoumdbe checkedwith a micrometerfor an out-of-
round condition. If the journals exceed0.001 in. (0,025 ram)
out-of-round, the camshaftshould be replaced.
The camshaft should also be checkedfor alignment. The best

methodis by use of "V" blocks and a dial indicator. The dial
indicator will indicate the exactamountthat the camshaftis out of
true. If it is out morethan 0.002 in. (0,051 mm)dial indicator
reading, the camshaft should be replaced. Whenchecking, the
high reading of the dial indicator indicates the high point of the
shaft. Examinethe camshaft bearings and if any bearing needs
replacement,replace all bearings.
Gearand Thrust Plate

[~ If the inspection indicated that the camshaft,gear andllhrust
plate were in good condition, the camshaftend play should be
checked.This clearanceshould be 0.001in. to 0.005 in. (0,025 to
0,127 mm).
Disassembly
~_~if the inspectionindicated that the shaft, gearor plate should
be replaced, the gear must be removedfrom the shaft. Support
the camshaftgear and press shaft out of gear.
E~ Thrust plate must be positioned so that woodruff key in 860028
shaft doesnot damageit whenshaft is pressedout of gear. Also,

supportthe hubof the gear or the gear will be seriously damaged.
Assembly
3"b assemblecamshaftgear, thrust plate andgear spacer ring to
camshaft, proceedas follows:
1.. Firmly supportshaft at backof front journal in an arbor press.

Place gear spacer ring and thrust plate over end of shaft, and
install woodruffkey in shaft keyway.
2. Install camshaftgearandpressit onto the shaft until it bottoms

against the gear spacerring. Theendclearanceof the thrust plate
should be 0.001-0.005in. (0,025-0,127ram)
860029
Camshaft Bearings
Removal
Camshaftbearings can be replaced while the engine is disassem-

bled for overhaul, or without complete disassembly of the engine
after camshaft and flywheel have been removed. Operation is
easier if crankshaft is also removed. See Crankshaft in this
section.
1. With camshaft and flywheel removed, drive out expansion plug

for rear cambearing by driving from inside. 860030
2. Position bearing pilot in inner bearing, install nut on puller

screw far enoughso puller screw can be threaded into pilot while
nut extends out front of block.
3. Install removersection onto puller screw, and then install screw

through cambore and thread it into pilot.
t\
E~ 4. using two wrenches, hold screw shaft and turn puller nut
to remove bearing.
EEl 5. Removepilot from shaft and install on drive handle with

shoulder to handle. Drive out front and rear bearings from outside
to inside of block.
instal|ation
860031
Inner bearing should be installed first to prevent damagingend
bearing with screw shaft.
[~ Bearing O.D.’s for number one and number two are
1.999-2.001 in. (5,077-5,083 cm) and numberthree is 2.009-2.011
in. (5,103-5,108 cm).
1. Removehandle from pilot. Install inner bearing on pilot.
2. Position inner bearing and pilot to rear of inner bearing bore.

install screw shaft (with removeradapter on it) through the block
from front of engine into pilot.
3. Align oil hole on bearing with oiJ hole from oil gallery. Snug
puller nut against adapter.
EEl 4. using two wrenches, hold screw shaft and turn puller nut
to pull bearing into place.
Oil hole is on top side of bearing and cannot be seen 86OO32
during installation. First align bearing oil hone with oil hole in
bore, and mark opposite side of bearing and block at bore to
easily index oil hole during installation.
2-16 E,0i,*Je,g
5. Attach drive handle to pilot, then place new number one
bearing on pilot.
E2~6. Align oil hole on bearing with oil hole from oil gallery and
drive bearing in from front of engine.
~4~ ~ The front bearing must be driven approximately l/e in.
behind front of cylinder block to uncoveroil hole to timing gear oil
nozzle.
7. Repeatstep (5) and (6) aboveto drive rear bearing into position
from rear of block. 860033
Rear bearing installed position is flush with inner edge of

rear cam bearing bore.
8. install a new expansion plug at rear bearing.
Camshaftinstallation
1. if crankshaft has been removed,install it at this time. Follow

procedures under the title Crankshaft in this section. If a new
camshaft is to be installed, coat cam lobes with G.M. Super
Engine Oil Supplement(G.M.P/N 1051858) and add rest of (:an
860034
crankcaseoil.
2. install the camshaft assemblyin the engine block, being careful

not to damagebearings or cam.
Es~ 3. Turn crankshaft and camshaft so that the vaJve timing

marks on the gear teeth will line up, then push camshaft into
position. Install camshaft thrust plate to block screws and tighten
them to 72-90 in. Ibs. (8-10 N-m).
E6~ 4. Check camshaft and crankshaft gear runout with a dial
indicator. The camshaft gear runout should not exceed 0.004 in.
(0,102 mm) and the crankshaft gear runout should not exceed 86OO35
0.003 in. (0,076 mm).
5. if gear runout is excessive, the gear will have to be removed,

and any burrs cleaned from the shaft or the gear replaced.
E7-7 6. Check the backlash between the timing gear teeth with a
narrow feeler gauge or dial indicator. The backlash should not be
less than 0.004 in. (0,102 mm)nor morethan 0.006 in. (0,152 mm).
7. Install timing gear cover with newgaskets. Install oil pan with
new gaskets and seaner. Connect oil drain tube.
860036
8. InstalJ harmonicbalancer as describedunder title TimingGear
(~ver in this section.
Eng~ine]eng 2-17
9. Install valve lifters and pushrods. install side cover with a new
gasket and sealer. Attach coil and wires. Install distributor,
positioning rotor to reference mark.
10. Pivot rocker arms over push rods. Adjust valve lash as
outlined under heading Valve Lash Adjustment.
11. Add oil to engine. Unstall the alternator and power steering
belts, then adjust tension. Checkand adjust timing.
Crankshaft
Removaland installation
1. Removemain bearing caps and connecting rod caps and lift

crankshaft out of cylinder block. Pushpistons to top of bores.
2. Inspect the crankshaft:
Main bearing journals are ground to 2.2983-2.2993 in. (5,8377-

5,8402 cm).
Crankpin journans are ground to 2.099-2.100 in. (5,331-5,334 cm).
These dimensions should be checked with a micrometer for

out-of-round, taper or undersize, mf the journals exceed 0.001 in.
(0,025 ram) out-of-round or taper, the crankshaft should
replaced or reconditioned to an undersize figure that will enable
the installation of undersize precision type bearings.
The crankshaft should also be checkedfor runout. To perform this

operation, support the crankshaft at the front and rear main
bearing journals in "V" blocks, and indicate the runout of both the
front center and rear center journals using a dial indicator. The
runout limit of eachof these journamsis 0.002 in. (0,051 mm).if the
runout exceeds 0.002 in. (0,051 mm), the crankshaft must
repaired or replaced.
3. Removerear main bearing oil seal.
4. Removeold bearings from cylinder block and caps. install new

bearings in the cylinder block and caps.
Main bearings with oil holes are the upper halves of the
bearings and are inserted between the crankshaft and cylinder
block.
5. Oil crankshaft journals and carefully place the crankshaft in the

bearings.
6. install all bearing caps and bolts. Tighten all main bearing cap
bolts, except the rear mainbearing, to 60-70 ft. Ibs. (81-95 N-m}.
VVhentightening rear main bearing cap, tighten bolts to 10-12 ft.
Ibs. (14-16 N-m) first, then tap end of crankshaft rearward ,with
lead hammer(this wilm locate bearing cap and bearing). Then tap
crankshaft forward (this will line up both upper and lower
crankshaft bearing thrust surfaces). Proceedwith final tighl:ening
of rear main bearing cap bolts to 60-70 ft. Ibs. (81-95 N.m)=
7. Checkmain bearing clearance and crankshaft end play. Install

new rear bearing oil seat. Instatl connecting rod bearings and
caps.
Connecting Rod Bearings

Connecting rod bearings are available in standard sizes and
undersizes of 0.001 in., 0.002 in., 0.010 in. and 0.020 in. (,0,025,
0,051, 0,254, 0,508 mm). These bearings are not shimmed and
when clearances become excessive the next undersize bearing
should be used.
Do not file rod or rod caps.
Removaland Inspection
1. Withdraw oil, disconnect oil drain tube and removeoil pan.
2. Removethe connecting rod bearing cap. Wipe bearing and

crankpin clean of oil.
L~ 3. Place a piece of Plastigage gauging plastic the full width of 860037

the bearing on crankpin (parallel to the crankshaft).
4. Reinstall the bearing cap and evenly tighten the retaining nuts
to 35 ft. Ibs. (47 N-m).
E~ Do not turn crankshaft with the gauging plastic installed.
E~ 5. Remove the bearing cap and, without removing the

gauging plastic, check its width at the widest point with the
Ptastigage scale.
if the crankpin is out-of-round be sure to fit the beariing to

the maximum diameter of the crankpin. If the flattened plastic is
not uniform from end to end in its width, the crankpin or bearing
is tapered, has a low spot or someother irreguiarityg Check the
crankpin with a micrometer for taper if the flattened gauging
plastic indicates morethan 0.001 in. (0,025 mm)difference.
860038
6. If the reading is not over 0.0009in. (0,0229 ram} or not less than
0.0014 in. (0,0356 mm)the fit is satisfactory. If however, the
clearances are not within these limits, replace the bearing with
the proper undersize bearing.
The bearings are not adjustable and no attempt should be

madeto adjust by filing or shimmingthe bearing caps.
installation
Newbearing clearance should be 0.00085-0.00135 in. (0,02159-

0,03429 mm).
1. Rotate the crankshaft after bearing adjustment to be sure the

bearings are not too tight.
2. Check connecting rod end clearance between connecting

rod cap and side of crankpin. See Engine Specifications for
clearance.
3. Install oil pan with new gaskets and seals. Connect oil drain
tube. Refill with engine oil.
CrankshaftBearings 860039
The main bearings are of the precision insert type and do not
utilize shims for adjustment, if the clearances are found to be
excessive, a new standard or oversize bearing, both upper and
mowerhalves, will be required.
If, for any reason, main bearing caps are replaced, shim-
ming may be necessary. Laminated shims for each cap are
available for service. Shim requirements will be determined by
bearing clearance.
The clearance may be checked by using Plastigage gauging

plastic. Whenone bearing is being checked, all the other main
bearing caps must be in place and tightened to specifications.
The main bearings used as service replacement are of high

quality with close tolerances of fit and will not require line
reaming on installations. The close dimensional tolerances en-
sure an equalized bearing surface at all points on the crankshaft
when replaced in sets.
Main bearings may be replaced without removing the

crankshaft.
1. Withdraw oil from crankcase. Disconnect oil drain tube. Re-

movethe oil pan.
2. Removethe spark plugs.
3. Remove cap on main bearing requiring replacement and

remove bearing from cap. Install a main bearing removing and
installing tool in the oil hole in the crankshaft.
Use tool J-6098-01. if such a tool is not available, a cotter

pin maybe bent as required to do the job.
4. Rotate the crankshaft clockwise as viewed from the front of the

engine. This will roll upper bearing out of engine.
5. Oil new upper bearing and insert plain (unnotched) end of the
bearing between crankshaft and indented or notched side. Rotate
the bearing into place.
6. Install new bearing in bearing cap. ]’he rear main bearing

journal has no oil hole drilling. To removethe upper bearing half
proceed as follows after cap is removed:
a. Use a small drift punch and hammerto start the bearing

rotating out of block.
Use a pair" of pliers to hold the bearing thrust surface to

the oil slinger, and rotate the crankshaft to pull bearing
out.
C° To install, start the bearing (side not notched]~ into

notched side of block by hand, then use pliers as before
to turn bearing half into place.
The last I/4 in. movementmaybe done by holding just the

slinger with pliers (taped jaws) or tap in place with a drift
punch.
7. Check bearing clearance per paragraph below.
Main Bearing Clearance
Plastigage gaugingplastic is a wax-like plastic material which will

compress evenly between the bearing and journal surfaces
without damaging either surface. To obtain the most accurate
results with gauging plastic, certain precautions should be ob-
served. If the engine is upside down, the crankshaft will rest on
the upper bearings and it can be assumedthat the total clearance
can be measured between the cap bearing and journal.
~ot~ To ensure the proper seating of the crankshaft, the rear
main bearing oil seamshould be removedand all bearing cap bolts
should be at their specified torque, in addition, preparatory to
checking fit of bearings, the surface of the crankshaft journa,I and
bearing should be wiped clean of oil.
1. Starting with the rear main bearing, removebearing cap.
Wipe oil from journal and bearing cap before applying

gauging plastic.
Engine/eng 2-21
EEl 2. Place a piece of gauging plastic the full width of the
bearing (parallel to the crankshaft) on the journal.
I~ Do not rotate the crankshaft while the gauging plastic is
between the bearing and journal.
3. Install the bearing cap and even{y tighten the retaining bolts to
60-70 ft. Ibs. (81-95 N.m).
4. Removebearing cap. The flattened gauging plastic will be

found adhering to either the bearing or journal. On the edge of
gauging plastic packing envelope there is a graduated scale 860041
measuring in thousandths of an inch.
5. Without removing the gauging plastic, check its com-

pressed width (at the widest point) with the graduations on the
gauging plastic envelope.
Normally, main bearing journals wear evenly and are not

out-of-round. However,if a bearing is being fitted to an out-of-
round journal be sure to fit to the maximumdiameter of the
journal. Jf the bearing is fitted to the minimumdiameter of the
journal, and the journal is out-of-round 0.001 in. (0,025 ram)
more, interference betweenthe bearing and journal will result in
rapid bearing failure. If the flattened gauging plastic tapers
toward the middle or ends, there is a difference in clearance
indicating a taper, low spot, or other irregularity of the bearing or
journal. Be sure to check the journal with a micrometer if the
flattened gauging plastic indicates more than 0.001 in. (0,025
ram) difference.
8. ff the bearing cJearance is not over 0.0035 in. (0,0889 ram)

{worn) or 0.003 in. (0,076 ram) (new), or less than 0.001 in. (0,025
ram), the bearing is satisfactory, if the clearance is not within 860042
these limits replace the bearing.

[~ If a new bearing cap is being installed and clearance is less
than 0.001 in. (0,025 ram), check for burrs or nicks; if none are
found then install shims as required.
7. A 0.002 in. (0,051 mm) undersize bearing may produce the

proper clearance. If not, it will be necessary to regrind the
crankshaft journal for use with the next undersize bearing.
[~E] Bearings are available in standard sizes and various und-

ersizes. See your parts catalog.
8. Oil newbearings with engine oil prior to installing end caps.

Proceed to the next bearing. After all bearings have been
checked, rotate the crankshaft to see that there is no excessive
drag.
2-22 Engine/eng
3r~ 9. Checkthe end play by forcing the crankshaft to its extreme
front position. Checkat the front side of the rear main bearing
with a feeler gauge. This clearance should be from 0.002-0.006 in.
(0,051-0,152 mm).
10. install a newrear main bearing oil seal in the cylinder block
and main bearing oil cap as described below.
Rear Main Bearing Oil Seal Replacement

r~o~ Care shouUd be taken when removing the rear crankshaft
oiE seal so as not to nick the crankshaft sealing surface.
[4~ 1.insert a screwdriver into the notches provided in the seal
retainer and pry the seal out. Take care not to damagethe
crankshaft sealing surface.
860043
2. inspect chamfer on crankshaft for grit, loose rust, and burrs.
(,’lean seal running surface on the crankshaft with a non-abrasive
cleaner.
EEl 3. Lubricate the inner and outer diameter of new seal with
engine oil. Install the seal on J-35621. Position J-35621 against
the crankshaft. Thread the attaching screws into the tapped holes
in the crankshaft.
4. Tighten screws securely. This will ensure the seal is ins;tailed

squaremyover the crankshaft. Turn handle until it bottoms then
remove J-35621.
Oil Seal Retainer Replacement

1. RemoveFlywheel and oil pan. Removescrews, nuts and seaJ
retainer. Removegasket.
2. Removerear crankcase oil seal as previously stated and clean DR1878

gasket surfaces on block and seal retainer.
[No-"~ VVhenever seal retainer is removed, a new retainer gasket
and rear crankshaft oil seal must be installed.
3,. Attach gasket to block. No sealer is required. Install seal

retainer, screws and nuts. Tighten to 135 in. Ibs. {15,3 N-m).
4. lnstaml oil pan. install rear crankshaft oil seal as outlined

previousny,install fl’y,wheel.
Piston and Connecting Rod DR1879
Piston and Rod Remova|
1. Withdraw crankcase oil Disconnect oil drain tube. Removeoil

pan.
2. Drain coolant from block and exhaust manifold, then remove

cylinder head.
Er,~ine/~nQ 2-23
3. Removeany ridge and/or deposits from the upper end of the
cylinder bores with a ridge reamer.
Movepiston to the bottom of its travel and place a cloth on

top of piston to collect the cuttings. After ridge and/or deposits
are removed,turn crankshaft until piston is at the top of its stroke
and carefully removecloth with the cuttings.
4. Checkconnecting rods and pistons for cylinder numberidentifi-

cation and if necessary, mark them.
5. Removeconnecting rod cap nuts and caps. Push the rods away
from the crankshaft and install caps and nuts moosely to their
respective rods.
6. Push piston and rod assemblies away from crankshaft and out
of the cylinders.
It will be necessary to turn the crankshaft slightly to

disconnect someof the rods and push them out of the cylinder.
Piston and Rod Disassembly
1. Install pilot of piston pin removingand instalming tool J-24086

on piston pin.
2. install piston and connecting rod assembly on support

and place assemblyin an arbor press. Press pin out of connecting
rod.
3. Removeassembly from press. Removepiston pin from support

and remove tool from piston and rod.
4. Piston pins are a matchedfit to the piston and not available

separately. Piston pins will not becomeloose enoughto cause a
knock or tapping until after prolonged use. in such cases a new
piston and pin assembly should be installed.
Piston pins should be capable of supporting their own weight in

either pin boss whencoated with light engine oil at 60° F. Higher
or lower temperatures wilm cause false indications. Pistons and
pins are serviced as assemblies.
Checkfit of used piston pins. Use a dial bore gaugeor telescoping

860046
snap gauge for the bore, and a micrometer for the pin. Wearlimit
on piston pin is production clearance plus 0.001 in. (0,025 mm).
Replace piston and pin assembly if wear is excessive.
CJeaning and Inspection
Clean varnish from piston skirts and pins with a cleaning solvent.
DO NOTWiREBRUSHTHE PISTONSKIRT. Clean the ring grooves
with a groove cleaner, and makesure oil ring holes and slots are
clean.
2-24 Englne/eng
Inspect the piston for cracked ring lands, skirts or pin bosses,
wavy worn ring lands, scuffed or damagedskirts, or eroded areas
at top of the piston. Replace pistons that are damaged or
otherwise show signs of excessive wear.
Piston and Rod Assembly
1. Lubricate piston pin holes in piston and connecting ~rod to

facilitate installation of pin.
:2. Position connectingrod in its respective piston so that flange or

heavy side of rod at the bearing end will be towards front of
piston (cast depression in top of piston head).
[2~ 3. install piston pin (~) on installer ® and pilot spring ~)
pilot (~ in support(~).
4. Install piston and rod on support, indexing pilot through piston

and rod.
5. Place support on arbor press, start pin into piston and press on
installer until pin pilot bottoms.
6. Remove installer and support assembly from piston and

connecting rod assembly. Check piston pin for freedom of move-
ment in piston bore.
Piston Rings
Piston rings are furnished in standard sizes as well as several
oversizes. See your parts catalog.
Oit control rings used on all engines consist of two segments

(rails) and a spacer.
Compressionrings in all engines are the deep section twist type,

0.0775-0.0780 in. (1,969-1,981 ram) wide.
This type compression ring takes its name, twist type, from its
installed position which is cocked or twisted. It assumesand
maintains this position for life because the upper edge of its
diameter is chamfered, making the ring unbalanced in cross
section.
[~ All compression rings are marked with the letter "GM"

cast in the upper side of the ring. Wheninstalling compression
rings, makesure the side marked"GM" is toward the top of the
piston.
Removal
I. Removepiston rings by expanding them and sliding them off

the ends of the piston. Tool No. J-8037 is available for this
purpose.
E..i~/..~ 2-25
2. Checkpiston ring grooves by carefully removingall particles of
carbon. Also check for burrs or nicks that might cause rings to
hang up.
installation
1. Select rings comparablein size to the piston being used.
It is important that each ring be fitted to its individual

cylinder for proper gap spacing and to its individual piston and
groove for proper clearance.
2. Slip the ring in the cylinder bore; then, using the head of a
piston, press the ring down into the cylinder bore about two
inches.
Using a piston in this way will place the ring square with
the cylinder wails.
r=~ 3. Checkthe space or gap betweenthe ends of the ring with a
feeler gauge.
4. ff the gap betweenthe ends of the ring is beJowspecifications,

removethe ring and try another for fit. 860048
5. Fit eachring separately to the cylinder in whichit is going to be

used.
6. New pistons, rings and cylinder bores wear considerabmy

during seating and gaps widen quickly; however, engine opera-
tion will not becomeseriously affected if ring gaps do not become
greaterthat 1,~2in.
[~ 7. Slip the outer surface of the compression ring into the
piston ring groove. Roll the ring entireay around the groove to
makesure that the ring is free and does not bind in the groove at
any point. If binding occurs, the cause should be determined and 880049
removedby carefully dressing with a fine cut file. However,if the

binding is causedby a distorted ring, install a newring.
8. Install the oil ring spacerin the oil ring groove and position gap
in line with piston hoJe. HoJdspacer ends butted and install steen
rail on top side of spacer. Position gap at least one inch to left of
spacer gap, then instal[ second rail on lower side of spacer.
Position gap at least one inch to right of spacer gap.
9. Flex the oil ring assemblyin its groove to makesure ring is free
and doesnot bind in the groove at any point, if binding occurs, the
cause should be determined and removed by carefully dressing 860050
with a fine cut fine. However, if the binding is caused by a
distorted ring, install a newring.
[3~ 10. Proper clearance of the piston ring in its piston ring
groove is very important in maintaining engine performance and
in preventing excessive oil consumption. Therefore, whenfitting
newrings, the clearances betweenthe top and bottom surfaces of
the ring grooves should be inspected.
[3~ 11. The compression rings should be fitted so that the
clearance is 0.0020-0.0035 in. (0,051-0,089 mm).
12. Assemblethe rings to the pistons as they are fitted and makea
final test of the ring fit in the grooves by repeating the fitting
procedure given above.
Expander ends must not align with the ring gap.
Piston and RodInstallation
1. Lightly coat pistons, rings and cylinder walls with light engine
oil.
[~ 2. With bearing caps removed, install tool J=6305-01 on

bearing cap bolts.
L~ I~ 3. install each piston in its respective bore, using tool
J-8037 on each assembly. The side of the piston with the cast
depressionin the head should be to the front of the cylinder block
and the oil hole on connecting rod toward the camshaft side of
the engine. Guide the connecting rod bearing into place on the
crankshaft journals with the long detail of tool J-6305-01. Use
J-8037 to compresspiston rings.
4. Oil bearings and install bearing caps. Install cap retaining

screws and nuts. "Tighten nuts to 35 ft. Ibs. (47 N-m). Checkthe
bearing clearance as described previously.
880051
5;. install oil pan gaskets, seals and oil pan. See Oil Pan. Connect V
oil drain tube.
6. Instalt cylinder head gasket and head. See CyKinder Head

lnstaiJation.
7. Refill crankcase and check for leaks. Test unit and check for
coolant leaks.
Cylinder Block
inspection
1. Checkthe cylinder block for cracks in the cylinder walls, water

jacket and main bearing webs.
860052
E,,~i.o/~o~ 2-27
EEl 2. Checkthe cylinder walls for taper, out-of-round or exces-
sive ridge at top of ring travel. This should be done with a dial
indicator (use TooJ J-8087). Set the gauge so that the thrust pin
must be forced in about 1/4 in. to enter gauge in cylinder bore.
Center gauge in cylinder and turn dial to "0". Carefully work
gauge up and down cylinder to determine taper and turn it to
different points around cylinder wall to determine the out-of-
round condition, if cylinders were found to have more than 0.002
in. (0,051 ram) out-of-round, boring will be necessary.
Repair
The performance of the following operations is contingent upon

engine condition at time of repair.
if the cylinder block inspection indicated that the block was

suitable for continued use except for out-of-round or tapered
cylinders, they can be conditioned by honing, or boring and
honing.
860{)53
If the cylinders were found to have messthan 0.005 in. (0,127 ram)
taper or wear, they can be conditioned with a hone and fitted with
0.001 in. (0,025 ram) oversize pistons. A cylinder bore of less than
0.005 in. (0,127 mm)wear or taper maynot entirely clean up when
fitted to a 0.001 in. (0,025 ram) oversize piston, if it is desired
entirely clean up the bore in these cases, it will be necessaryto
rebore for an oversize piston, if morethan 0.005 in. taper or wear
exists, they should be bored and honed to the smallest oversize
that will permit complete resurfacing of all cylinders.
Piston Selection
Replacementpistons are available in two sizes, see the appropri-

ate parts catalog for part numbers.The size identification of the
piston is markedin ink on the piston top.
To determine the correct size of piston needed, measure the

cylinder bore with a telescope gauge and micrometer, and
subtract the base cylinder bore diameter, 4.000 in. (10,180 cm)
from the measureddiameter. Next locate this dimension on the
Piston Selection Chart. The numbershownon the chart in the box
above the dimension is the marking on the piston which should
be used.
2-28 Er~|ne/eng
ExampJe"A’:
Cylinder Bore Measurement 4.002 in. (10,165 cm} (Worn Bore)

Base Cylinder Bore
Diameter 4.000 in. (10,160 cm}
Difference 0.002 in. (0,051 ram)
The number in the box above 0.002 (0,051 mm)in is $7. There-
fore, in this case a 0.001 in. (0,025 mm)oversize piston marked
,would be used.
ExampBe"B":
Cylinder Bore Measurement 4.032 iin. (10,241 cm) (Bored Out Bore)
Base Cylinder Bore
Diameter 4.000 iin. (10,160 cm)
Difference 0.032 iin. (0,813 mm)
"The numberin the box above 0.032 in. (0,813 mm)is 4. In this
e×ampfe, a 0.030 in. (0,762 ram) oversize piston marked4 would
be used.
SERVICE PISTON MARKING
DR4649
Boring
1. Before using any type boring bar, the top of the cylinder" block
should be dressed to remove any dirt or burrs. This i,.~ very
important. Otherwise, the boring bar maybe tilted which would
result in the rebored cylinder wall not being at right angles to the
crankshaft.
2. The piston to be fitted should be checked with a micrometer,

measuringjust below the lower ring groove and at right angles to
the piston pin. The cylinder should be bored to the samediameter
as the piston and honed to give a clearance of 0.0025-0.0035 in.
(0,064-0,089 ram).
3. The instructions furnished by the manufacturer of the equip-

rnent being used should be carefully followed.
E~i~ 2-29
Honingand Piston Fit
1. Whenthe cylinders are to be honed only for use of a standard

piston or for final finishing after they havebeenrebored to within
0.002 in. (0,051 ram) of the desired size, they should be finished
with a hone. Roughstones maybe used at first and fine stones for
the final operation.
2. Place the hone into a cylinder bore and expandthe stones until
the hone can just be turned by hand. Connecta 1~ in. (0,217 ram)
electric drill to the hone and drive hone at drill speed while
moving hone up and down entire length of cylinder until hone
begins to run free. During this operation a liberaJ amount of
kerosene should be used as a cutting fluid to keep the stones of
the hone clean. Move hone slowly up and down with rough
stones, but movehone up and down rapidly enoughwith the fine
stones to producea final bore finish of very fine surface scratches
in a cross-hatch pattern of approximately 45° to 60°. The marks
should be clean but not sharp, and free from embeddedparticles
or torn or folded metal.
3. Expand the stones against the cylinder bore and repeat the
honing operation until the desired bore diameter is obtained.
4. Occasionally during the honing operation, the cylinder bore

should be thoroughly cleaned and the piston selected for the
individual cylinder checkedfor correct fit.
5. Checkfit of the aluminumpistons in the following manner:
Thoroughly cleat’1 cylinder bores with soap and hot water

to removeall grit particJes.
ao Measure the cylinder bore diameter with a tenescope

gauge and micrometer 21~ inches (6,35 cm) from top
cylinder bore at 90° from crankshaft axis.
b. Next measurethe diameter of the piston skirt just below

the lower ring groove and at right angles to the piston
pin.
c. if the difference is greater than the maximum allowable

(see Boring, step 2), try another piston or lightly honethe
cylinder bore to obtain the proper fit.
d, Should the difference be less than the minimumallowa-

ble {see Boring, step 2), try another piston. If proper fit
cannot be obtained, it will be necessary to rebore the
cylinder to the next oversize piston.
e. Mark each piston after fitting to correspond with the

cylinder to which it has been fitted. Proceed to hone
cylinders and fit the remaining pistons.
2-30 Engino/erlg
Handlethe pistons with care and do not attempt to force
,them through the cylinder until the cylinder has beenboredto
correct size. This type piston can be distorted throughc~mreless
handling.
6. Thoroughlyclean the cylinder bores with hot water and soap.

’.Scrub well with a stiff bristle brushandrinse thoroughlywith hot
water, it is extremelyessential that a goodcleaningoperation be
performed.If any of the abrasivematerial is allowedto remainin
the cylinder bores, it will rapidly wearthe newrings andcylinder
bores, in addition, the bearingwill be lubricated by the contami-
nated oil The bores should be swabbed several times with light 866054
engineoil anda clean cloth andthen wipedwith a clean dry cloth.
Cylinder should not be cleanedwith keroseneor gasoline. Clean
the remainderof the cylinder block to removethe excessmaterial
spreadduring the honing operation.
Distributor LowerBearing
"[’he distributor lowerbearingis a bronzebushingpressedinto the
lower side of the engineblock. Its upperinside diameterpilots the
distributor shaft, and the outside diameterextending below the
block pilots the oil pump.
’.Some engines have a thrust washer at the upper end of the

bushing bore. Thethrust washer,whereused, maybe replaced at
the sametime the bushing is replaced.
Thelower bushingwill ordinarily require only a clearanceor wear

check during engine overhaul. Whendistributor shaft-to-bushing
clearanceexceeds0.0035in. (0,0889 ram) the bushing should 86O055
replaced as follows with oil pumpand distributor removed:
[1=~ 1. Install tool J-9534-01into bushing and using ~= slide

hammer,remove the bushing.
Protect your eyesfromfragments.Wearsafety glasseswhen
striking these tools, handles,drivers, etc. Tool endmaymush-
=room after being repeatedly struck. Always grind off any re|led
~ges before using tool. Use soft face hammerswhenever
possible.
13 2. Usinga drift up through bushingbore, drive thrust washer
(if installed) out of bore andremovefrom block.
:3. Clean bushingbore in block and checkfor burrs or damage.
13 4. if thrust washer was removed, start new washer in

position in bore anddrive into place using tool J-9534-01.
!5. Usingtool J-9535with driver-bolt in driver handle,install driver

into newbushingfrom large inside diameter.
860056
L.LJ 6. Placebushingand driver on block anddrive the bushingin
position. Depth is determined by tool bottoming against the
block.
7. Remove tool from bushing. It is possible that the bushingwith

minimum I.D. will collapseenough,during installation, to slightly
seize the installer arbor, mf this happens,removeinstaller tool
using slide hammer in driver bolt hole of driver handle.
This will not damage

the bushingand the tool is designed
for this purpose,shouldit occur.
Circulating Pump
Removal
1. Openpetcocks on port side and drain coolant from block and
exhaust manifold. Disconnectwater hose from circulating pump.
2. Loosenfour screwsholding circulating pumppulley to circulat-
ing pump.
860057
3. Loosenalternator bracket bolts and removealternator belt.
Removecirculating pumppulley and bolts° Unscrewbolts and
removethe circulating pumpfrom the engine.
Pull the pumpstraight out of the block first, to avoid
damageto impeller.
inspection
if the seal is leaking replace the pump.if the bearingis roughor

allows excessive sideways movement of the shaft, replace the
pump.If the impeller has excessiveerosion replace the pump=
|nstaflation
This pumphas a special shaft and bearing assemblyand a
special seal assemblyintendedfor marineservice. Donot substi-
tute with an automotive pump.
1. Apply Gasket Sealing Compoundto a new pumpto block

gasket. Install pumpassemblyon cylinder block and tighten bolts
securely.
2. Install circulating pumppunley. Attach alternator belt and

adjust. Refer to Genera||nformationsection for specifications.
3. Connectcoolant hosesto circulating pump.Lakeor tank test

unit andcheckfor leaks.
OiR Pan Replacement
Removal
1. Remove
oil using a suction pump.
2-32 Engine/eng
2. Removeoil withdrawal tube. Removescrews, oil pan and
,gasket.
ilnstallation
1. Thoroughlyclean all gasket sealing surfaces. Apply R’rv sealer

¯ to the front andrear of the block.
2. Install gasket on the block. Install oil pan. Tighten 1/4×20screws

to 80 in. Ibs. (9 N-m) and ~ex18screws to 165 in. ibs. (18,6 N-m).
dlnstall oil drain tube and fill crankcasewith engine oil.
OU Pump Replacement
12~ The oil pumpconsists of two gears (~) and a pressure relief
’valve (~) enclosed in a two-piece housing ©. The pumpis driven
#ore the distributor driveshaft which in turn is driven by a helix
gear on the camshaft.
"The oil pumpis flange mountedto the cylinder block with two
bolts, and piloted on the outside of the lower distributor bronze
bearing. Oil pressure passes through an opening in the mounting
"Flange to the cylinder block, then into the full flow oil filter. The
pumpcover is equipped with the pressure regulator valve that
=regulates oil pressure at approximately 40-60 PSI (135,1-202,6
kPa) at 2000 RPMThe pumpintake is of the fixed screen type.
=meshscreen (~ filters out small particles of dirt and sludge which
may be present.
A baffle incorporated on the intake screen has been

designed to eliminate pressure loss due to suddensurging stops,
turns, and acceleration.
IIn the event that a screen becomes plugged a steel grommet

opens and bypasses oil to the pump.
Removal and Disassembly
1. Withdraw oil. Disconnect oil withdrawal tube. Removescrews,

oil pan and gasket. Removeoil withdrawal tube fitting from oil
pan.
2. Remove oil pickup tube clamp bolt. Remove two flange

mounting bolts. Removepump and screen as an assembly.
860058
:3. Removefour cover attaching screws, cover, gasket, idler gear,
and drive gear and shaft.
,4. Removepressure regulator valve and valve parts. If necessary,

remove oil pump suction pipe and screen by pulling from pump
Inousing.
Engine/eng 2-33
Do not disturb oil pickup pipe on screen. This pipe is
located at assembly.
5. Washall parts in cleaning solvent and dry using compressed

air.
inspection
Shouldany of the following conditions be found during inspec-
tion operations, the defective parts should be replaced.
1. inspect pumpbodyfor cracks and excessivewear. inspect oil

pumpgears for excessive wear or damage.
2. Checkshaft for loosenessin the housing.Checkinside of cover

for wearthat wouldpermit oil to leak past the endsof gears.
3. Checkthe oil pick-up screen for damage

to screen or relief
grommet.
4. Checkpressureregulator valve plungerfor fit in cover.
Assemblyand installation
1. Placedrive gear andshaft in pumpbody. Install idler gear so

that smoothside of gear will be towardthe cover.
2. install a newpumpto cover gasket to ensure correct end
clearanceof the gears.
3. Install suction pipe and screen assemblyto pumpbody and

install coverandattachingscrews.Tightenscrewsto 65-75in. Ibs.
(7-8 N-m)andcheckto see that shaft turns freely.
4. Install regulator valve plunger, spring, retainer andpin.
5. Align oil pumpdriveshaft slot to matchwith distributor tang.

Install oil pumpto block, positioning flange over distributor lower
bushing. Useno gasket.
Oil pumpshouldslide easily into place. If not, removeand

relocate slot or determineother problem.
6. Attach and tighten oim pickup tube clamp.
7. Install oil panusing newgasketsand seals.

[~] 8. Install withdrawaltube fitting to pan; leave screwloose.
Orient fitting and attach withdrawal tube. Then tighten both 31576
fitting screwandflare nut to 15-18ft. Ibs. (20-24N-m}.
9. Fill crankcase
with oil.
Oil Filter BypassValve
Inspection
Removethe oil filter and check the spring and fiber valve for
operation. Checkfor a cracked or broken valve.
Replacement
If replacement is necessary:
1. Removethe valve by prying it out with a screwdriver. 2888
2. Install a newvalve and seat it by tapping into place using a 9Ae

in. thin wall deep socket and hammer.
3. Install oil filter accordingto manufacturer’sinstructions.
Front Engine Mount
Removal
[2~ 1. Removetwo lag screws and washers from mounts;.
34732
~/~ 2. Uft engine with hoist capable of lifting at least 1000 lb.
(454 kg) minimum capacity hoist to allow removalof front mount
and bracket.
[3-~ 3. Removefour mount screws and lock washers. Remove
front engine mount and spacer (port side) from engine.
Disassembly
[~ ~ Prior to disassembly of front mount assembly, mea-

sure distance between large washer on bracket and small washer
on lower mount and record for reference during reassernbly. 18367
[5-~ [~ 1. Put wrench on flat of trim adjustment shaft and

socket on top nut, and remove engine bracket and spacer.
22657
16383
0
o
@
m 22656 16351 22654
[~ 2. Removetwo bolts from engine bracket and removerubber

mount assembly.
[-~ 3. Removelower nut and washeron shaft and removeshaft
from lower mount.
[~ 4. Uponcomplete disassembly, check pieces and replace
where necessary.
Reassemb|y
Z~ 1. Place one nut and washeron trim shaft, then set trim
adjustment shaft in lower mount, |nstaRI remaining washer, and
screwon lower nut. Makesureat least three shaft threadsextend
through
nut. Tightennuts finger tight, do not tighten at this time.
[~ 2. Place engine bracket spacer on shaft.
[~] 3. Attach rubber mountto engine bracket with two bolts and
tighten to 30-35ft. Jbs. (41-47N.m).
[~ 4. Place engine bracket assemblyon shaft with large and
small washerand tighten nut to 50-60ft. lbs. (68-81N-m).
22653
Installation
[~ 1. Attach engine bracket and port side spacer to the engine
with two long bolts and lock washers(port side) and two short
bolts and lock washers(starboard side). Tighten long port side
bolts to 48-56ft. Ibs. (65-76N.m)andstarboardbolts to 32-40ft.
Ibs. (43-54N-m).
[~] ~ 2. To reset engine height to original position, refer to
measurement points and dimensionrecorded in Step 4 of Remov-
al. Loosennuts to adjust shaft and mountposition to desired
height. Hold one nut and tighten the other to 115-140ft. Ibs. 16382
(156-190N.m).
Safety Releted 2-36 34731

Engme/eng
Z~ 3. Install lag screwsend tighten securely.
Front Mount Height Adjustment

,/~k 1. Support engine with a hoist capable of lifting at least 1000
rib. (454kg).
[~ 2. Removeboth lag screws from lower front mount.
[~ Z~ 3. Loosen nuts securing lower mount to trim shaft.

Reposition lower mount to desired position, then retighte, lower
mountnuts to 115-140 ft. Ibs. (156-190 N-m). 16367
11-~ ~ 4. install two lag screws in lower mount and tighten

securely.
High-Rise Exhaust Elbow Replacement

Removal
1. Loosen all four hose clamps. Lubricate exhaust pipe with a

soapy water solution, and slide hose down off exhaust elbow.
:2. Loosenhose clamp and disconnect cooling hose from inside of 2972
exhaust elbow. Then remove hose fitting.
3. Removethe two screws ~) and swing anchor bracket out

of the way. Then remove the two nuts and lock washers ~.
[1~ 4. Loosenthe elbow with a soft hammer,then lift it off the

manifold. Removeand discard the elbow gasket.
Installation
1. Thoroughly clean the manifold and elbow gasket sulrfaces.

Apply Gasket Sealing Compoundto both sides of a new gasket,
2888
,and place it on the manifold.
34729
Engineleng ~ Safety Related 2-37 2284~

[~ 2. Mount the elbow on the manifold. Install the throttle
anchor bracket, and secure with the two screws (~ and the two
nuts and lock washers(~).Tighten all four to 12-14 ft. Ibs. (18-19
N.m). Slide the exhaust hose all the way onto the elbow.
3. Install hose fitting on the inside of elbow and connect cooling

hose.
~] 4. Position the upper clamps in the top two channels and

tighten them securely, install and securely tighten the two lower
clamps.
34728
5. Reconnectthrottle cable to carburetor and throttle linkage
plate. Securewith cotter pin.
Exhaust HoseReplacement
Removal
1. Remove high rise exhaust elbow following procedure

High-Rise Exhaust Elbow Replacement.
[~] 2. Removeclamps and slide hose off exhaust pipe.

34727
installation
[~] ~ One end of exhaust hose has two ribs © around the
circumference. Position this end up when installing hose to
ensure secure attachment.
1. Place two No. 64 hose clamps over exhaust pipe if they were
removed.
r~ 2. Lubricate inside diameter of hose with a soapy water
solution to ease installation, and slide hose all the way onto
exhaust pipe. Place two No. 64 clamps around top section of 22647
hose.
3. Complete hose and high-rise elbow installation following

procedure in High-Rise Exhaust Elbow Replacement.
16350
//~ Safety Related 2-38 Engme/eng

Exhaust (Flapper) Valve Replacement
Removal
1. The exhaust valve is at the upper end of the exhaust pipe.
Removeexhaust elbow and exhaust hose.
2. Usinga small drift or punch@,pushthe exhaustvalve pin
out of the exhaustpipe.
~=~ [~ 3. Removepin and valve. Push out two rubber bush=
ings. 6373
installation
8~ 1. Apply Scotch Grip Rubber Adhesive to two new rubber
bushingsand push into exhaust pipe.
[~ 2. Lightly lubricate exhaustvalve pin with oil. Position
valve in exhaust pipe with long side of valve down. Pushpin
through bushingand exhaustvalve until flush with both sides of
pipe. Checkexhaust valve for freedomof movement.
If the valve is not positionedproperly (long lip down), 6375A

will restrict exhaustflow andfail to preventwater frombackingup
into exhaust system. Boat performancecould be adversely af-
fected, and major powerheaddamagecould occur.
3. install exhausthoseand elbow.
6376
6377
20034
1
6675 6675
Engine Coupler Replacement
Removal
1. Removeengine from boat following instructions in Engine
Removal
andInstallation section.
if coupler is beingreplaceddueto coL~pierfailure (rubber

hub of spiined hub), checkengine alignmentafter installing new
coupler. See EngineAlignmentin EngineRemova| and Instal|a-
tion section. 6710
2. Cut tie strap holding flywheel housing drain hose to starter

motor.
[~ [~ 3. Take out screws holding flywheel housing cover (~),
then slide out cover.
[~ 4. Unscrewouter nut on ground stud, and take off lock
washerand electrical leads. Removeinner nut, lock washerand
washer. Removesimilar ground stud hardwareon opposite side
of block.
6712
5. Removescrews and washersholding shift bracket, and move
bracket aside.
6. Unscrewremaining flywheel housing bolts, lock washersand
washers. Note position of clamps so they can be installed in
original position.
[~ 7. Lift flywheel housingoff engineblock and set aside.
[~ 8. Unscrewsix nuts and lock washers,then pulm coupler off
flywheel.
6714
2-40 Eng~ne/eng
installation
L~ 1. Slide coupler onto crankshaft studs, install lock washers
and nuts. Use a crowfoot wrenchand tighten nuts to 40-45t"t. Ibs.
(54-61 N.m).
ET~ 2. Install flywheel housing, Place clamps in their original

positions, and attach shift bracket. Tightenscrewsto 28-36t"t. Ibs.
138-49 N.m).
Z~ 3. Place washer, lock washer and nut on ground stud. Tighten
inner nut to 35-40 ft. ibs. (47-54 N-m). Attach electrical leads 6711A
ground stud. install lock washerand tighten outer nut securely.
install ground stud hardware on opposite side of block.
~8~ 4. Slide flywheel cover up into place, install screws and
tighten them to 60-84 in. Ibs. (7-9 N.m).
Eg~ 5. Attach flywheel housing drain hose ~) to starter motor
with tie strap.
6. Install engine in boat following instructions in Engine Removal

and installation section.
20034
14704
Engine Specifications
1. GeneralSpecifications
Type - No. of Cylinder ..................... 4 - In-line

Bore and Stroke .......................... 4.000 in. x 3.60 in,
Piston Displacement ....................... 181Cu. in. (3.0 Liter)
Cylinder No. {front to rear) .................. 1- 2- 3- 4
Firing Order ............................. 1- 3- 4- 2
Compression Ratio ........................ 9.3 to 1
Thermostat Opens at ...................... 160° F
Full Throttle Operating Range ............... 4200-4600 RPM
2. Engine Dimensions, Fits and Adjustments
Pistons:
Type ................................ Flat Head
Clearance Limit at Top Land .............. 0.0255 - 0.0345 in.
Clearance Limit at Skirt .................. 0.0025 - 0.0035 in.
Compression Ring Groove Depth .......... 0.209- 0.211 in.
Oil Ring Groove Depth .................. 0.190 - 0.199 in.
Piston Rings:
Compression Ring
Material ......................... Cast iron
Type ............................ Radius Face (Upper)
Tape Face (Lower)
Coating - Upper Ring ............... Molybdenum
Coating - Lower Ring ............... Wear Resistant
Width ........................... 0.0775 - 0.0780 in.
Gap ............................ 0.010 - 0.020 in. (Upper)
0.013 - 0.025 in, (Lower)
Oil ring
Material ......................... Flat Spring Steel
Type ............................ Multi-piece RaiJ Expander and Spacer
Coating (rail) ..................... Chrome
Width (Piston Groove) .............. 0.188 - 0.189 in.
Gap {Ring) ....................... 0.015 - 0.055 in.
Width (Ring) ...................... 0.154 - 0.160 in.
Expanders ....................... One-Piece Expander-Spacer
Piston Pins:
Length .............................. 2.990 - 3.010 in.
Diameter ............................. 0.9270 - 0,9273 in,
Clearance in Piston (new) ................ 0.0003 - 0,0004 in.
Wear Limit in Piston .................... 0.001 in,
Clearance in Rod ....................... 0.0008 - 0.0021 in.
2-42 Er~ine/er~
EngineSpecifications
Connecting Rods:
Material .............................. Drop Forged Steel
Length CL to CL ....................... 5.700 in.
Connecting Rod Bearing
Material ......................... M400
Effective Length ................... 0.792 - 0.822 in.
Clearance ........................ 0.00085- 0.00135in.
End Play ......................... 0.008 - 0.015 in.
Crankshaft:
Material ............................. Nodular Cast Iron
End Play ............................. 0.002 - 0.006 in.
End Thrust Taken By .................... Rear Main Bearing
Crankpin Journal Diameter ............... 2.099 - 2.100 in.
Main Bearing
Type ............................ Precision Removable
Journal Diameter .................. 2.2983- 2.2993 in.
Length .......................... 0.822 in. (rear)
0.830 in. (others)
Clearance ........................ 0.0003- 0.0029 in.
Camshaft:
Camshaft Bearing
Material ......................... Steel BackedBabbitt;
Journal Diameter x Bearing Length .... 1o8692in. x .860 in.
Bearing Outer Diameter - Nos. 1 and 2 . 1.999 - 2.001 in.
Bearing Outer Diameter - No. 3 ....... 2°009- 2.011 in.
Type of Drive ......................... Gear
Crankshaft Gear Material ................ Helical Cut Nodular Cast iron
Camshaft Gear Material ................. Helical Cut Bakelite and Fabric Composition
Lobe Lift ............................. 0.253 in. _+ 0.005 in.
Valve Systems:
Lifter Type ........................... Hydra~uJic
Rocker Arm Ratio ...................... 1.75 to 1
Valve Lash Adjustment -
Intake and Exhaust (hot) ............ 3~ to 1 Turn DownFrom "Zero Lash" Point
Valve Face Angle ...................... °45
Valve Seat Angle ....................... =
46
Stem to Guide Clearance -
Intake ’Valve ...................... 0.001(],- 0.0027in.
Stem to Guide Clearance -
Exhaust Valve .................... 0.0010- 0.0027 in.
RecommendedValve Seat Width
Intake ........................... lh2 in, to I/~6 in.
Exhaust ......................... Vie in. to s~2in.
Valve Systems(cont.):
Outer Valve Spring Free Length ........... 2.08 in.
Outer Valve Spring Pressure
Lb. @ in ......................... 78-86 @1.66 in.
EngineLubrication:
Type Oil Pump ........................ Gear
Normal Oil Pressure .................... 40-60 PSi @ 2000 RPM
Crankcase Capacity- Quarts .............. 31~ (4 with newfilter)
Oil Grade Recommended:Service SG-Meeting GMSpec 6094

32° F. and Above ....................... SAE 30
0° F. to 32° F ........................... SAE 20W-20
Below 0° F ............................ SAE 10W
WerecommendDuraPlus Synthetic Motor Oilwhich is specially formulated for heavy duty marine use.
DuraPlus Synthetic Motor Oil provides superior anti-wear qualities, especially important during
prolonged high speed operation, nt also neutralizes acids created in aim internal combustion engines.
This motor oil is formulated to offer superior protection against corrosion and to resist oxidation and
high temperature sludge formation°
The use of multi-viscosity oils is not recommended.Disregard any reference to multi-viscosity

oil printed on engine. Such reference is intended for automotive use only, not marine use.
Fuel Grade Recommendation .............................. See General Information section
2-44 Engirteleng
TorqueSpecifications- All Models
The following specifications are for screw sizes not shownotherwise:
SCREW FT. LBS IN. LBS. N.rn

SiZE
No. 6 7- 10 0,8- 1
No. 10 2- 3 25- 35 :3 - 4
No. 12 3-4 3;5-45 4-5
1/4 5- 7 60 - 80 7- 9
~6 10- 12 120- 140 14- 16
¾ 18 - 20 220 - 240 24 - 27
Use a reliable torque wrenchto tighten the parts listed to prevent straining or distorting the parts or
possibly damagingthe threads. These specifications are for clean threads only. Dirty threads produce
friction which prevents accurate measurementof tightness, it is important that these torque specifica-
tions be strictly observed. Overtightening to any extent maydamagethreads, thus preventing proper
torque from being obtained, requiring replacement or repair of the damagedpart.
E~ { FT. LBS.} (ON.LBS.}
Adaptor- Oil Pressure Sender 10-14 - 14-19

Alternator - Bracket to Engine 26-30 - 35-41
Camshaft Thrust Plate - 72-90 8-10
Circulating Pump 13-17 - 18-23
Crankshaft Oil Seal Retainer 135 15,3
Distributor Clamp 20 - 27
Exhaust Elbow 12-14 - 16-19
Flywheel Beilhousing 28-36 38-49
Flywheel Cover 60-84 7-9
Front Mount - Port 48-56 65-76
Front Mount - Starboard 32-40 43-54
Oil Pan (1/4 x 20) 80 9
Oil Pan(5/16 x 18) 165 18,6
Oil PumpCover 65-75 7-8
Oil Withdrawal Tube Fitting 15-18 20-24
Power Steering PumpBracket 26-30 35-41
Starter Motor 30-36 41-49
Starter Motor Bracket 16-19 22-26
Raw-water Pump Bracket 13-17 18-23
Thermostat Housing 12-16 16-22
Timing Chain Cover 8O 9
Valve Cover - 65 7,3
TorqueSpecifications - (Cent,)
( FT. LB$. } ( iN. LBS. ] {~
Connecting Rod Cap 35 47

CrankshaftOil Seal Retainer 135 15,3
FlameArrestor Cover 30-40 3,4-4,5
Flare - Oil WithdrawalTube 15-18 20-24
Flywheel and Coupler 40-45 54-61
Flywheel Bellhousing 35-40 47-54
intake/Exhaust Manifold 20-25 27-34
Cylinder Head
Step 1 35 47
Step 2 65 88
Step 3 95 129
Intake/Exhaust Manifold 20-25 27-34
MainBearing Cap(exc. rear) 60-7O 81-95
Main Bearing Cap, Rear
Step 1 10-12 - 14-16
Step 2 60-70 - 81-95
Oil Pump 110-120 12-14
FlameArrestor to Carburetor 65-80 7-9

Flywheel and Coupler 10-15 - 14-20
PowerSteering PumpBracket 13-15 - 18-20
Oil Filter Oneturn after contact

Retainer - Oil PanDrain 1 5-18 - 20-24
Sender,Oil Pressure 10-14 - 14-19
Sender, Water Temperature I8-22 - 24-30
Spark Plugs 20 - 27
2-46 E.~i./er~
Section3
4.3 GL, GS, Gi

5.7 GL, Gi
Volvo Penta Engines
Table of Contents
Balance Shaft Service - V-6 ............ 3-17 Front Engine Moun",s .................. 3-39
Balance Shaft Bearing Replacement..... 3-20 General Specifications ................. 3-44
Camshaft ............................ 3-20 High-Rise Exhaust Elbow Replacement.. 3-40
Camshaft Lobe Lift, Measuring ......... 3-26 Intake Manifold ........................ 3-3
Circulating Pump..................... 3-38 Intermediate Pipe Fleplacement ......... 3-41
Connecting Rod Bearing Replacement... 3-31 Lubrication System.................... 3-23
Crankshaft ........................... 3-28 Oil Pan .............................. 3-24
Cylinder Block ........................ 3-36 Oil Pump............................ 3-24
Cylinder Head ........................ 3-10 Oil Seal, Rear Main Bearing ............ 3-27
Engine Coupler Replacement........... 3-42 Piston, Ring and Connecting Rod ....... 3-32
Engine Specifications ................. 3-45 Timing Chain and Sprocket ............. 3-15
Exhaust Hose Replacement ............ 3-41 Torque Specifications .................. 3-47
Exhaust Manifold .......... ............ 3-5 Valve Lifter, Hydraulic .................. 3-6
Exhaust (Flapper) Valve Replacement... 3-42 Valve Spring and Seal Repair ............ 3-9
Safety Warnings
Before working on any part of the engine, read the section called Safety at
the end of this manual.
Unless instructed otherwise, always disconnect the battery cables from
the battery before working on electrical systemto prevent possible sparks
or arc, ing in the enginecompartment.
Before starting engine after repair or maintenanceprocedures, alwaysmake
sure enginecompartment is free of fuel vaporsto prevent possible fire and
explosion.
Whenworking on an engine that is running or being cranked, use extreme
care to avoid getting hands, fingers or clothing caught in the alternator,
power steering pump, supply pump, and circulating pUmprbelts, pulleys
and other movingparts.
Entline/eng 3-1
General Motors Tools
Item Part
Number
Balance Shaft Bearing Service Kit ................. J=38834
Bearing Puller ............................... J-6098-01
Bearing Remover .............................. J-26941
Carbon Remover ............................... J-8089
Crankshaft SeaFInstaller ........................ J-35468
DamperPuller and installer ...................... J-39046
Dial indicator Set ............................... J-8520
Dial Indicator .................................. J-8087
Driver Handle ................................. J-8092
Volvo Penta AmphenolCrimping Tool ........... P/N 322696
Pin Remover& installer ......................... J-24086
ReamerTool Set ............................. J-5830-02
Reamer0.003 in. O.S ............................ J-5715
Reamer0.013 in. O.S ............................ J-6036
Ring Compressor ............................... J-8037
Seal Installer ................................. J-35468
Seal Installer ................................. J-35621
Shaft installer ................................ J-36996
Spring Tester .................................. J-8056
Stud Installer .................................. J-6880
Stud Protector ................................. J-5239
Stud Remover ............................... J-5802-01
Vacuum Pump .............................. J-23738-A
Valve Spring Changer ......................... J-5892-C
OrderDirectly from:
Kent-MooreTool Division
28635 Mound Road
Warren, MI 48092
1-800-345-2233
Price and ordering information are available from Kent-Moore

Tool Division.
Material Required
DuraPlusSynthetic Motor Oil or equivalent

MolykoteLu b rica nt
Plastigage (Green)
GMSilicone Rubber Sealer
Liquid Neoprene
For additionamservice information not coveredin this manual,

obtain the appropriate ChevroletEngineWorkshopManualfrom:
HelmInc.
P. O. Box 07130
Detroit, MI 48207
3-2 Engine/eng
intake Manifold
Removal
[1~ EEl 1. Drain coolant from both sides of block and mani-
folds.
2. Disconnect:
~/~ a. Battery cables from battery.
b. Coolant hoses at thermostat housing. 28287
~. Throttle cable from carburetor/TBI unit and anchor block.
d. Crankcase ventilation hose from rocker arm covers (both

sides).
e.Wire at temperature gauge sender unit and e,ngine

wiring harness from alternator.
f. Distributor high tension and ignition primary leads from

coil. 5.7 Gi: Disconnect 2-wire connector (brown and
pink) from the distributor. 25916
3. Remove:
Distributor cap and mark the position of the rotor on the

housing. Scribe a line on distributor housing and i!ntake
manifold for reassembUyin the same position. Remove
the distributor.
b. Alternator" and alternator mountingbracket from engine.
c. Carburetor/TE}l unit fuel line from carburetor/TE}l unit and

fuel pump(s).
d. Oil pressure sending unit.
e. Manifold attaching bolts and solenoid bracket. Lift mani-

fold from engine. Discard front and rear seals and
gaskets.
f. ff manifold is to be replaced, transfer: carburetor/TBI

unit, thermostat and housing (use new gasket), throttle
cable anchor bnock assembly, distributor clamp and
temperature sending unit. Transfer additional hardware
as required.
Installation
1. Clean gasket and seal surfaces on manifold, block and cylinder

heads.
2. Install:
a. Newmanifoldseals on block andnewgasketson cyfin-der
heads.Usesealer at water passages
and whereseals butt to
gaskets.
i
[33 Note IOn those enginesnot havingfront andrear manifoldseals, DR225

place a 3/16 in. beadof GMSiUiconeRubberSealer on the front and
rear ridges of the cylinder case. Extendthe bead1/2 in. up eachcylin-
der headto seal andretain the manifold side gaskets.
V-6 Models
Tightenall bolts except®to 35 ft. Ibs. (47 N-m)followingse-
quenceshown.Tighten@to 41 ft. Ibs. (56 N-m).
EEl V-6 Modelswith ribbed aluminumoil pan.

Tightenall bolts in sequence
usingthree steps.
a. 27in. lb. (3 N-m).
b. 106in. lb. (12 N-m).
c. 132in. lb. (15 N-m).
V-8 Models
Tightenall bolts to 89 in. Ibs. (10 N-m).
c.Distributor with rotor andaligned exactly as markedduring removal.

t
Note!If enginewascrankedwhile distributor wasout, completeigni-
tion timing proceduremustbe followed. Seethe appropriateIgnition
Circuit in Electrical/Ignition Systems
ServiceManual.
d. Alternator with mountingbracket.

e. Distributor capandhigh tensionleads. Seethe GeneralInfor-
mationsectionin Electrical/Ignition ServiceManual
for correct
firing orderandsparkplugwire routing.
f. Oil pressuresendingunit.
3. Connect:
a. All electrical connections.ApplyBlackNeoprene
Dip on all
exposedconnections.
b. Carburetorfuel line.
c. Throttlecable.
d. All waterhoses,andcloseall drain petcock.
e. Bothcrankcaseventilation hoses.
f. Batterycables.
9. Start engine.Adjustignition timing, carburetoridle speedand
mixture. Checkfor leaks.

Exhaust Manifold
Removal
1. Drain water from exhaust manifolds.
2. Disconnect water hose from manifold.
3. Loosen upper exhaust hose damps, then remove higlh rise

elbow.
4. Removemanifold attaching nuts and washers. Discard nuts.
inspection
1. inspect for cracks.
2. To pressure check manifold, use a fabricated plate as

pictured ~) and a new elbow gasket (~) to seal water passage
manifold. Be sure to apply sealer to gasket. Install rubber drain
caps to manifold and secure with clamps. Attach a Volvo Penta
pressure gauge © to the water inlet hose. A bushing can be made
to secure pressure gauge to hose. With the pressure gauge
attached to the manifold, submergemanifold in water. Pressurize --__51 DR2642
the manifold to 10-15 PSi (22-25 kPa) and check for leaks.
Manifold should not leak around clampsand plate. If so, retighten
clamps or reseal plate. No drop in pressure should be realized.
installation
6~ ~] 1. Clean mating surfaces on manifold and head. Install
new exhaust gasket, then install manifold and secure with new
Iocknuts and washers. Tighten nuts ~) to 20-26 ft. Ibs. (27-35
N.m).
2. Install a newgasket and high rise elbow to manifold. Tighten V-6 Models
28287
bolts to 12-18 ft. Ibs. (16-24 N-m).
3. lnstalt exhaust hose and secure with clamps.
4. Connectwater hose. install and tighten drain petcocks.
5. Start engine and checkfor fuel leaks.
25916
HydraulicValve Lifter
Checking
HydraulicValveLifter
Whencheckinghydraulic valve lifters, remember that grit, sludge,

varnish, or other foreign matterwill seriously affect their opera-
tion. If any foreign substanceis found in the lifters or engine
whereit maybe circulated by the lubrication system, a thorough
cleaning job mustbe doneto avoid a repetition of lifter trouble.
To help preventlifter trouble, the engineoil andoil filter mustbe

changedas recommended in General information section. The
engine oil must be heavy-duty type (for Service SG) and must
also conform to General Motors Specification 6094Mto avoid
detrimental formation of sludge and varnish. Werecommend
Volvo Penta DuraPlus" Synthetic Motor Oil. The boat owner
should be specifically advised of these requirements whenthe
unit is delivered. Faulty valve lifter operation usually appears
under one of the following conditions:
1. RappingNoiseOnly WhenEngineis Started:

When the engineis stopped,any lifter on a camshaftlobe is under
pressureof the valve spring; therefore, leak downor escapeof oil
from the lower chambercan occur. Whenthe engine is started, a
fewseconds maybe requiredto fill the lifter, particularly in colder
weather, if noise occurs only occasionally, it maybe considered
normal, requiring no correction. If noise occurs frequently, how-
ever, checkfor either oil too heavyfor prevailing temperatures,or
excessivevarnishin lifters.
2. intermittent RappingNoise:
An intermittent rapping noise that appearsand disappearsevery
few secondindicates leakage at check ball seat due to foreign
particles, varnish, or defective surface of checkball or seat.
Replacelifters as necessary.
3. Noiseat Idle and LowSpeed:
if one or morevalve lifters are noisy at idle speedand up to

approximately 1200RPM,but quiet at high speeds, it indicates
excessiveleak downrate or faulty checkball seat or plunger. With
engine idling, lifters with excessive leak downrate maybe
spotted by pressing downon eachrocker arm abovethe push rod
with equal pressure. Reconditionor replace noisy lifters.
3-6 Engine/eng
4. GenerallyNoisyat All Speeds:
Checkfor low or high oil level in crankcase.Highoil levels will be

c, hurnedby crankshaftandwill force air bubblesinto the lifters. Low
oil levels allow pump to pumpair at high speed.With engineidling,
strike each rocker’ arm abovethe push rod several sharp blows
with a mallet; if noisedisappears,it indicates that foreign material
waskeepingcheckball from seating. Stop engineandplace lifters
on camshaftbasecircle. If there is lash clearancein anyvalve link-
age,it indicatesa stucklifter plunger,wornlifter bodylower,end, or
worncamshaftlobe.
5. LoudNoiseat NormalOperatingTemperatureOnly: ,,,~/

I1: a lifter developsa loud noisewhenthe engineis at normaloper-
ating temperature, but is quiet whenengineis below normaltem-
perature, it indicates an excessivelyfast leak downrate of scored
Nfter plunger.Reconditionor replacelifter.
Removal ¯ .~. ~ // ~ ~-.-:-....~ y..,,,-- ,,
1. Withair hoseandcloths, cleandirt fromcylinder headsandadja-

cent parts to avoidgetting dirt into engine.It is extremelyimportant
that nodirt getsinto the valvelifters.
2. Remove
intake manifold. Remove
exhaust manifold.
ET1 3. Remove rocker armcovers. Do not pry, if covers stick use

rubber mallet andstrike cover end to jar loose. Loosenrocker arm
nuts or screwsandpivot the rocker arms@free of the pushrods.
[:3[] 4. V-6 Models: Removepush rods ®. Unscrewretainer @
with restrictors @.Remove
lifters that require service.
5. V-8 Models: Remove push rods ® and removevalve lifters

6:) that require service. Placelifters in a wooden
block havingnum-
bered holes or use other suitable meansof identifying themac-
cordingto original position in the engine.
ROTATING
- NORMAL,
OK - NOTROTATING
E2~ 5.7 Gi Models: Removepush rods ®. Unscrewretainer @
with restrictors @.Remove
lifters that require service.
6. If less than a completeset of lifters is being removed,immedi-

ately disassemble oneor twofor presence of dirt or varnish.If lifters
containdirt or varnish, it is advisableto remove aNlifters for re-
placement.Otherwise,it will be satisfactory to service only those
lifters that are not operatingproperly.
GALLED- SHOULD
BE REPLACED
- SOFT, WORN
E4~7. Examine the camcontact surface at lower endof lifter body.
If this surface is excessively worn, galled or otherwise damaged,
discard the lifter assembly.In this case, also examinethe mating
camshaftlobe for excessive wearor damage.
E n9ine/er.,g 3-7
Installation
Note i Before installing
anynew
lifters, coatthebottom
of thelifter with
Molykote
or its equivalent.
1. Bnstall valvelifters in cylinder block. If anynewlifters or a new

camshafthas beeninstalled, an additive containing EPlubricant
such as G.M. Engine Oil supplementmust be addedto the crank-
caseoil.
2. V-6 ModelsOnly: Install retainer with restrictors. Tighten re-

tainer bolts to 145in. Ibs. (16,4 Nm).
3. Install pushrodsonto lifters. Install intake manifold.
4. Pivot rocker armsin place. V-6 ModelsOnly:Tighten screwsto

40 ft. Ibs. (54 Nm).V=8ModelsOrfly: tighten the adjusting nuts
zero lash.
Valve LashAdjustment
- V-8 only
1. Baroverthe enginecrankshaftuntil markon harmonic balancerlines up

withcenterof "0" markonthe timingtabto achieve’q-DC"(TopDead Center).
Thismaybedetermined bythe valvesfor number6 cylinderrocking,andboth
valvesfor number
1 cylinderareclosed.If thevalvesfor number
1 cylinderare
rockingandthe valvesfor thenumber 6 cylinderare dosedtheenginecrank-
°shaft
. shouldberotated360
E~2. Valveadjustment is madeby looseningthe rockerarmstudnut until

thereis playin thepushrodandthentightenslightly to remove anyfreeplayof
thepushrod. Thismaybedetermined byrotatingpushrod,with fingersasthe
nutis tightened.When thepushroddoesnotreadilyrotate,the clearance has
beeneliminated.Theadjustingnut shouldbetightenedoneadditionalturn
°) to placethelifter plunger
(360 in thecenterof its travel.Nofurtheradjust- DR2104
mentis required.Withtheengine in this position,thefollowingvalvesmaybe

adjusted.
Exhaust- 1,3, 4, 8
Intake- 1,2,5, 7
3. Crankthe engineonerevolution(360 °) until the timingmarkis at "TDC"

again.Thisis number 6 firing positionandcanbeverifiedbycylindernumber
1 valvesrockingandboth the number 6 cylinder valvesclosed.Withthe
enginein this position,thefollowingvalvesmaybeadjusted.
Exhaust - 2: 5, 6, 7
Intake- 3, 4, 6, 8
4. Install rockerarmcoverswith newgaskets.
V-6Models:Tightenscrewsto 62-115in. Ibs. (7-13 Nm).

V-8Models:Tightenscrewsto 45 in. Ibs. (50 Nm).
5. Install exhaust
manifold.
Start engine
andcheck
for oil leaksat rockerarm
covers.
3-8 Englne/e~
[~ Do not attempt to turn the adjusting nut one full turn while
the engine is operating. Adjustment in this mannerwill not allow
the lifters to bleed down. This would result in valve train damage,
probably bent push rods. For those who prefer to adjust the valve
lash while the engine is running, the preferred methodwould be
to find the "zero lash" point as described aboveand then ,,;lowly
turn the adjusting nut 1/4 turn. Wait for the lifter to bleed down
(several engine revomutions)and again turn adjusting nut 1/,~ turn.
Continue this adjust and wait cycJe until nut is one complete turn
down from "’zero lash" point. Repeat sequence on rem;~ining
valves.
DR2103
Valve Spring and Seal Repair
Removal
[2~ 1. Removerocker arm cover.
;!. Remove spark plug, rocker arm, and push rod on the cylinder(s)
to be serviced.
L~ 3. mnstall Air Line Adapter tooa J-23590 to spark pmugport and
apply compressedair to hold the valves in place.
~-~ 4. Using tool J-5892-C to compressthe valve spring, remove

tlhe valve locks, valve cap and vaave spring and damper.
5;. Remove
the vaJve stem oil seal.
Insta|iation
1. install seal over valve stem and seat against head.
2. Set the valve spring and damper, valve shield and valve cap in
place. Compressthe spring with tool J-5892-Cand install oi0 seal
in the 0ower groove of the stem, makingsure the seal is fiat and
not twisted.
[No=~ A light coat of oil on the seal will help prevent twisting.
3. Install the valve locks and release the compressortool making

sure the locks seat properly in the upper groove of the valve stem.
Grease may be used to hold the locks in place while

releasing the compressor tool
4. Using VacuumPumpJ-23738-A, apply vacuumto the va0ve cap

to makesure no air leaks past the seal
5. Install spark plug and tighten to 22 ft. Ibs. (30 N-m).
6. Install and adjust valve mechanismas previousJy outlined.
Engine/eng 3-9
Cylinder Head
Removal
1. Drain water from block and exhaust manifolds. Removeintake

and exhaust manifold.
2. Removevalve covers and spark plugs.
3. Loosen rocker arm nuts and turn rocker arms aside. Remove
pushrods. if lifters are to be serviced, removethem at this point.
Otherwise protect the lifters and the camshaft from the entrance
of dirt by covering the area with clean cloths.
4. Removecylinder head bolts, cylinder heads and gasket. Place

cylinder heads on bench, supporting them at each end on blocks
of wood to prevent damageto gasket faces of heads.
Disassembly
1. Removerocker arms nuts, ball seats and rocker arms.

[~] 2. Using tool J-8062, compressthe valve springs and remove
the valve keys. Release the compressor tool, and removerotators
or spring caps, oil shedders, springs and spring dampers, then
removeoil seals and spring shims.
Somecylinder heads use exhaust valve springs with a

shorter free length than the intake valve springs.
3. Removevalve from bottom of cylinder heads and place them

and their respective valve springs in a rack in their proper
sequenceso they can be assembledin their original positions.
Cleaning
DR3123
[~ 1. Clean all carbon from combustion chambers and valve
ports using tool J-8089,
[~] 2. Thoroughly clean the valve guides using tool J-8101.
3. Clean all carbon and sludge from push rods and rocker arms.
4. Clean valve stems and heads on a buffing wheel.
5. Clean carbon deposits from head gasket mating surfaces.
Inspection
DR3124
2. Inspect the cylinder head for cracks in the exhaust ports,

combustion chambers, or external cracks to the water chamber.
3-10 Engine/eng
3. Inspect the valves for burned heads, cracked faces or darnaged
stems°
[3 4. Measure valve stem clearance as follows:
a. Clampa dial indicator on one side of the cylinder head

rocker arm cover gasket rail.
b. Locate the indicator so that movementof the valve stem

from side to side (crosswise to the head) will cause
direct movementof the indicator stem. The indicator
stem must contact the side of the valve stem just above DR2101
the valve guide. ¯ \
c. Drop the valve headabout IAs in. (1,6 ram) off the. valve
seat.
d. Movethe stem of the valve from side to side using light

pressure to obtain a clearance reading, if clearance
exceedsspecifications, it will be necessaryto reamvalve
guides for oversize valves.
J
[5~ 5. Checkvalve spring tension with tool Spring Tester J-8056.
10375
[~ On all models, springs should be compressed and should
check 76-84 poundsat 1.70 in. (34-38 kg at 43 ram) and 1!;)4-206
poundsat 1.25 inches (88-93 kg at 32 ram). Weaksprings affect
power and economy and should be replaced if below 70 pounds
(32 kg).
Repair
1. Valve GuideBore:
Valves with oversize stems are available for inlet and ex-
haust valves in the following sizes, 0.003 in., 0.015 in., and 0.030
in. (0,076, 0,381, 0,762 ram) (intake only). Use the reamer sizes 860007
from ReamerTool Set J-6830 to ream the bores for new w~lves.
2. Rocker ArmStuds - V-8 Only:
Rocker arm studs that have damagedthreads may be replaced

with standard studs. If the studs are loose in the head, oversize
studs, available in 0.003 in. or 0.013 in. (0,076, or 0,330 ram)
oversize, maybe installed after reaming the holes as follows:
[7---] a. Removeold stud by placing tool J-5802-01 ~) over the

stud, installing nut and flat washerand removingstud by
turning nut. DR2105
E.gl.~I..g 3-11
b. Reamhole for oversize stud using ReamerJ-5715 for
0.003 in. (0,076 mm) oversize and Reamer J-6036 for
0.013 in. (0,330 ram) oversize.
c. Coat press-fit area of stud with hypoid axle lubricant.

install newstud using tool J-6880 ~). Tool should bottom
on head.
Do not attempt to install an oversize stud without reaming

stud hole.
3. Valve Seats: DR2107


contact betweeneach valve and its seat in the head is imperative
away.
Several different types of equipment are available for reseating

valve seats; the recommendations of the manufacturer of the
proper results.
Regardless of what type of equipment is used, however, it is

essential that valve guides be free from carbon or dirt to ensure
proper centering of pilot in the guide.
a. lnstall expanding pilot in the valve guide bore and

b, Place roughing stone or forming stone over pilot and just

clean up the valve seat. Usea 46~ stone for both the inlet
and exhaust valve seats.
C. Removeroughing stone or forming stone from pilot,

install finishing stone on pilot and cut just enoughmetal
from the seat to provide a smooth finish.
d. Narrow downthe valve seats to the proper width for the

intake and exhaust. See Engine Specifications.
°This operation is done by grinding the port side with a 30
stone to lower seat and a 60° stone to raise seat. ~~:~. -~ ~m
e. Removeexpanding pilot and clean cylinder head care- 1042~

operations.
~ Valve seats should be concentric to within 0.002 in.

(0,051 ram) total indicator reading.
3-12 eo~i,~/~
4. Valves:
Valves that are pitted can be refaced to the proper angle, en;~uring
correct relation between the head and stem on a valve refacing
machine. Valve stems which show excessive wear, or valves that
are warped excessively should be replaced. Whena valve head
which is warped excessively is refaced, a knifeedge will be
ground on part or all of the valve head due to the amountof metal
that must be removedto completely reface. Knife edges lead to
breakage, burning or preignition due to heat localizing on this
knife edge. if the edgeof the valve headis less than 1/3z in. (0,792
ram) thick after grinding, replace the valve.
a. If necessary, dress the valve refacing machine grinding

°wheel to makesure it is smoothand true. Set chuckat 45
b. Clampthe valve stem in the chuck of the machine.
c. Start the grinder and movethe valve head out in line

d.Turn the feed screw until the valve head just contacts
wheel. Movevalve back and forth across the wheel and
eo Continue grinding until the valve face is true and smooth

all around vamve.If this makesthe valve thin, the valve
must be replaced as the valve will overheat and burn.
f. Removevalve from chuck and place stem in "V" block.

Feed valve squarely against grinding wheel to grind any
pit from rocker arm end of stem.
Only the extreme end of the valve stem is hardened to

resist wear. Do not grind end of stem excessively.
g. After cleaning valve face and cylinder head valve seat of

grinding particles, makepencil marksabout 1/4 in. apart
across the valve face, place the valve in cylinder head
and give the valve one-half turn in each direction while
exerting firm pressure on face of valve.
h. Remove valve and check face carefunly. If aal pencil marks

have not been removedat the point of contact with the
valve seat, it will be necessary to repeat the refacing
operation and again recheck for proper seating.
Assembly
[~ Whenreplacing valve springs, refer to the latest parts

catalog for ordering information.
r~ 1. Starting with number 1 cylinder, place the valves in the
designated ports and assembleall but the seal and locks. Then,
using tool J-8062, compressthe spring (~) and install the seal
and locks ©. Seethat the seal is flat and not twisted in the valve
stem groove, and that the locks seat properly in the valve stem
groove. Notice that only the exhaust valves have rotators (~.
[~ Place vane spring in position with the closed coil end

[~ 2. Check the installed height of the vane springs, using a
narrow, thin scale cut away at the bottom ~). Measurefrom the C03107
top of the shim, or spring seat, in the head to the top of the valve
spring shield, if this is found in excess of 111/ls in. (42,86 mm),
install a valve spring seat shim, approximately ~A6in. (1,59 mm)
thick. At no time should the spring be shimmed to give an
installed height of less than 13/4 inch (44 ram).
--®
Installation
1. Wipeoff engine block gasket surface and be certain no foreign

material has fallen into the cylinder bores, bolt holes, or the valve
lifter area. it is good practice to clean out bont honeswith an air
hose.
2. fnstali new head gasket on cylinder bJock. Dowelsin the block

will hold the gasket in position. Alwayshandle gaskets carefully to
avoid kinking or damageto the surface treatment of the gaskets.
DO NOTuse any type of sealing material on head gaskets. The
gaskets are coated with a special lacquer to provide a good seal, 47267
once the parts have warmed up.
V-6 Models
This engine has special marine head gaskets. Do not
substitute automotive head gaskets.
3. Clean gasket surface of cylinder head and carefulny set in place

on the engine block dowel pins.
I(o° 1
o
4. Clean and lubricate the head bolts with Gasket Sealing Com- @@@@
pound. InstalE bolts.
[~ ~ 5. Tighten the head bolts with a torque wrench, in three N DR2254

progressive steps, following the sequenceshown.
V-8 Models
Step 1 - 25 ft. Ibs. (34 N-m)
Step 2 - 45 ft. Ubs. (61 N-m)
Step 3 - 65 ft. Ibs. (88 N.m)
47277
3-14 E~ine/eng
NoteI Damageto thecylinderblockthreadscanresultif bolts arenotlubri-
catedwith Gasket SealingCompound
prior to installationor if the bolts are
\
_ y
tightenedexcessively.Usean accuratetorquewrench wheninstalling head
bolts anddonotovertighten. Uneventighteningof thecylinderheadbolts can
distort the cylinderbores,causingcompression loss andexcessive oil con-
sumption.
’Timing Chain and Sprocket
Balancer and Cover Removal ]] ® 47287
1. Remove
alternatorandpowersteeringbracketbolts.
;2. Remove
drculatingpump
pulley.
3. Remove
harmonic
balancerpulley bolts andpulley.
[~ 4. tnstall tool J-39046

®to harmonic
balancer,andturn puller screwto
remove balancerfromcrankshaft.
5. Draincoolingsystem
anddisconnect
hoseat circulatingpump.
47347
6. Removecirculating pump screwsandswingalternatorandpowersteering
bracketsaside. Remove circulating pump
anddiscardgaskets.
7. Remove
timingchaincoverscrewsandcover.
Notej V-6Models equippedwith compositecovers.Replacecoverwhen

evercoveris removed,
gaskets
areintergral to coverandarenot servicable.
1. Pryoil sealoutof frontof coverusinga largescrewdriver.
[~ 2. Install newseal with lip towardinside of cover. LJse tool

J-35468@to drivesealinto position.
Timing Chain Replacement
1. Remove
harmonic
balancerandtimingchaincover.
E~2. Crankengineuntil "O"markson camshaftandcrankshaftsprockets

are in alignment. In this position, engine is timed to fire
no.4 cylinder.
D c ’ o
3. Remove camshaftsprocketbolts. Remove sprocketandtiming chainto-
gether.Sprocket
is a slight press-fitfor approximately
1/8inch.If sprocket
does
notcome off easily,a light blowwitha plastic-faced
hammerontheloweredge
of thecamshaftsprocket shoulddislodgeit.
E~4. Install timingchainoncamshaftsprocket.Holdthe sprocketvertical

with thechainhangingbelow.Alignthecamandcranksprockettimingmarks,
thenattachthechainto the cranksprocket.
47307
5o Align dowel in camshaft with dowel hole in sprocket and instanl
sprocket on camshaft.
Do not hammersprocket onto camshaft. This may loosen

rear camshaft welsh plug.
6. Draw sprocket onto camshaft using the mounting bolts.
7. Lubricate the timing chain with engine oil.
Timing Chain Cover Installation
1. Coat the cover gasket with sealer and place in position over
dowel pins in cylinder block.
2. Lubricate timing cover seal lip with engine oil and place cover
in position over dowel pins.
3. install bolts and tighten to 80 in. Ibs. (9 N.m).
HarmonicBalancer installation
1. Coat timing chain cover seal area on balancer hub with engine
oil.
2. Align keywayand start balancer on to crankshaft.

[~ 3. Using appropriate end of tool J-39046 threaded into
crankshaft, or a large washer and a zAs-20 × 4 in. bolt and nut
threaded into center hole in crankshaft, tighten nut to seat
harmonic balancer on crankshaft.
4. Removebolt and washer, anstall belt pulley and tighten screws

to specifications.
5. Threadz/is-20 × 2 in. bolt and thick washerinto crankshaft and

tighten to specified torque. 34715
6. InstalJ circulating pumpand pulley. Attach water hose to pump.
7. Unstall aUternator and power steering pumpbrackets.
8. Instalm aJternator and powersteering belts and adjust tension to

specifications.
3-1 6 Engine/eng
Balance Shaft Service - V-6 Only
Removal
lP. Removedistributor per instructions in the appropriatesection in

Electrical/Ignition SystemsWorkshopManual. Give special at-
tention to markingposition of rotor in relation to distributor base
andintake manifo!d.
2. Remove
intake manifold and circulating pump.
34796
3. Remove
screws securing pulley and harmonicbalancer.
4. UseDamperPuller J-39046to removeharmonicbalance r.
5. Remove
oil pan.
6. Remove
screws securing timing chain cover and remove
cover.
1 Compositecover mustbe replaced whenremoved,integral

~ ~No~e
34797
gaskets andseals are not serviceable.
~=~7. Loosenbalance shaft driven gear screw ~).
[3~ [~ 8. Removethe two screws securing camshaft sprocket,

then unscrewthe nut securing camshaftsprocket. Remove
sprocket
andtiming chain.
Note
.... I Whenremovingthe nut, the stud maycomeout with it. If
this happens,separate the nut and stud after removingsprocket
andtiming chain. 348O4
9. Remove
balanceshaft drive gear.
10. Remove screw(loosenedearlier) securing balanceshaft driven

gear, then removegear.
L~ 11. Remove
the two balance shaft retainer screws and remove
retainer.
[~ 12. Tapbalance shaft and front bearing assemblywith a soft

faced hammeras shownto remove. 34802
-6] i ! 1"o DR5010

Insta|lation
[~ 1. Dip forward bearing in clean motor oil. mnstall balance

shaft and bearing assembly using Driver Handle J-8092 and Shaft
Installer J-36996.
2. install retainer screws (~ and tighten to 120 in. Ibs. (14

N.m).
3. With the balance shaft drive gear temporarily instalned, turn

camshaft so its timing mark is straight up. Removedrive gear.
DR5013
4. Install driven gear, then rotate balance shaft by hand to make
sure there is clearance between the balance shaft and the lifter
retainer. ReplaceJilter retainer if necessary.
5. install balance shaft driven gear screwfinger tight.
6. Turn balance shaft so the timing mark on the drive gear points
straight down.
7. Install the drive gear so the timing markis aligned with the
timing mark on the driven gear. Secure drive gear with retaining
stud. Tighten to 12 ft. Ibs. (16 N-m).
34802
[~ ~ Before installing the camshaft sprocket and chain,

make sure the timing mark on the crankshaft sprocket points
straight up and the marks (~ on the balance shaft gears are
aligned.
DR5014
3-18 Eng|ne/eng
[4~ 8. Hold camshaft sprocket and chain with sprocket 1Liming
mark pointing straight down. Place chain on crankshaft sprocket,
makesure timing marks are aligned, position camshaft sprocket
on stud and secure to camshaft with nut.
9. Install the two camshaft sprocket-to-camshaft screws.

[5~ 10. Tighten the camshaft sprocket-to-camshaft screws and
nut to 21 ft. Ibs. (28 N.m}.
[6~ 11. Tighten the balance shaft driven gear-to-balance shaft
,,;crew to 15 ft. Ibs. (20 N-m)plus an additional 35 degrees. 34804
34806
34807
Balance Shaft Bearing Replacement
The balance shaft and front bearing are serviced as an assembly.
Whenservicing the rear bearing the engine must be removed
from boat.
Rear Bearing Removal
1. Removebell housing coupler and flywheel.
~] 2. Drive out balance shaft plug.

DR5019
[~ [~ 3. Removerear bearing using Balance Shaft Bearing
Service Kit J-38834 and Bearing RemoverJ-26941.
Rear Bearinglnstallstion
[~ 1. Dip bearing in clean motor oil and install with service kit
J-38834.
El 2. Install balance shaft plug.
3. Install bell housing coupler and flywheel.
Camshaft
Removal
1. Removedistributor per instructions in the appropriate section

in Electrical/Ignition Systems Workshop Manual Give special
attention to marking position of rotor in relation to distributor
base and intake manifold.
2. Removeintake manifold and circulating pump.
3. Removerocker arm covers, valve lifters, and push rods.

DR5012
4. Removepulley, harmonic balancer, timing chain cover, timing

chain, and camshaft sprocket. V-8 Models Only: Removecam-
shaft thrust plate.
3-20 Engine/eng
!5. V-8 Models Only: Removefuel pumpand push rod.
[4~ 6. Install two ~8-18 x 4 in. bolts in camshaft sprocket bolt
holes and carefully pull out camshaft. Use care not to damage
camshaft bearings.
inspection
The camshaft has five bearings, all with the samejournal diame-
1:or of 1.8692 in. to 1.8682 in. (4,7477 4,7452 cm). These
dimensions should be checked with a micrometer for an out-of-
round condition, if the journals exceed 0.001 in. (0,025 mm) 47317
out-of-round, the camshaft should be replaced.
The camshaft should also be checked for alignment. The best

methodis by use of "V" blocks and a Dial Indicator tool J-8520.
The dial indicator will indicate the exact amountthat the camshaft
is out of true. If it is out more than 0.002 in. (0,051 ram) dial
indicator reading, the camshaft should be replaced. Whencheck-
ing, the high reading of the dial indicator indicates the high point
of the shaft. Examinethe camshaft bearings and if any bearing
needs replacement, replace all bearings.
Camshaft Bearing Removal
Camshaft bearings can be replaced while engine is disassembled

for overhaul, or without complete disassembly of the engi~ne. To
replace bearings without complete disassembly, remove the
camshaft and crankshaft leaving cylinder heads attached and
pistons in place. Before removing crankshaft, tape threads of
connecting rod bolts to prevent damageto crankshaft. Fasten
connecting rods against sides of engine so they will not be in the
way while replacing camshaft bearings.
1. With camshaft removed,drive out expansion plug at rear of the

rear camshaft bearing. Drive it out from the inside.
This procedure is based on removal of the bearing nearest

center of the engine first. With this methoda minimumamountof
llurns is necessary to locate the remover in position to remove
next bearing.
2. install nut on puller screw and turn to end of threads on puller

screw using tool J-6098-01.
3. index pilot over screw with open end toward nut on puller
screw,
4. Insert remover with shoulder toward number3 bearing, making

sure a sufficient amountof threads are engagedon the puller.
!5. Using two wrenches, hold screw shaft with one wrench while
!Iurning the front nut with the other wrench. After removing
bearing from block, repeat operation for number2 bearing.
E,~i~,g 3-21
6. RemovetooU and reassemble tool to remove number 4 bearing
from rear of engine.
7. Assembleremover on driver handle and removefront and rear

bearing.
CamshaftBearing installation
The camshaft front and rear bearing should be installed first.

These bearings winl act as guides for the pilot and center the
remaining bearings being pulled into place.
[~ 1. Assembleremover and installer tool on driver handle and

install camshaft front and rear bearings by driving towards center
of cylinder block.
2. Using Tool Set J-6098, with nut then thrust washerinstalled to

end of threads, index pilot in camshaft front bearing and install
puller screw through pilot.
3. Index camshaft bearing in bore (with oil hole aligned as

outlined below}, then install remover and installer tooJ on puller
screw with shoulder toward bearing.
47337
o Numberone cam bearing oil hole must be positioned so
that oil holes are equal distance from 6 o’clock position.
Number two through number four bearing oil holes

must be positioned at 5 o’cUock position (toward left side
of engine and at a position even with bottom of cylinder
bore).
¯ Number five bearing oil hole must be in 12 o’clock

position.
EEl 4. using two wrenches, hold puller screw while turning nut.
After bearing has been pulled into bore, removethe remover and
installer tool from puller into bore, remove the remover and
installer tool from puller screw and check alignment of oil hole in
camshaft bearing.
5. install remaining bearing in the same manner, nt will be

necessaryto index pilot in the camshaftrear bearing to instaUl the
rear intermediate bearing.
6. Coat new camshaft rear plug O.D. with GMNo. 1052080

sealant, or equivalent, and install flush to 1/32 in. (0,792 mm}deep.
Camshaftinstallation 47327
1. Lubricate camshaft journals with engine oil
[~ Whenever a new camshaft is installed, lubricate the cam-

shaft lobes with Molykote or its equivalent. Anso add one can of
G.M. Engine Oil Supplementto crankcase oil.
2. instaln two ~6-18 x 4 in. bolts in camshaft bolt holes. Install

camshaft, being careful not to damagebearing. V-8 ModelsOnly:
install thrust plate. Tighten screwsto 105 in. Ibs. (11,9 N-m).
3- 2 2 Ertgine/eng
:3. Install sprocket and timing chain.
4. install timing chain cover, harmonic balancer, pulley and

,circumating pump.
5. V-8 Models Only: Install push rod and fuel pump.
6. Connect coolant hose.
7. Install valve lifters, pushrods, intake manifold and distributor.
8. V-8 ModelsOnly: Adjust valve lash.
9. Install rocker armcovers.
Lubrication System
:Description and Operation
The oil pumpconsists of two gears ~) and a pressure relief

valve (~) enclosed in a two-piece housing ©, and driven from the
,distributor driveshaft whichin turn is driven by a helix gear on the
.camshaft.
It is flange mounted to the cylinder block with two bolts and

piloted on the outside of the lower distributor bronze bearing.
Oil passes through an opening in the mounting flange to the

,cylinder block, then into the full flow oil filter.
The pumpcover is equipped with the pressure regulator valve

that regulates oil pressure at approximately 40-60 PSi (276-414
kPa) at 2000 RPM.
~] The pump intake ~) is of the fixed screen type. A mesh

screen filters out small particles of dirt and sludge which maybe
47357
present.
A baffle incorporated on the intake screen has. been

,designed to eliminate pressure loss due to suddensurging stops.
In the event that a screen becomes plugged, a steel grommet

,opens and bypasses oil to the pump.
[~ A full flow oil filter is externally mountedto the cylinder

block on the left side of the engine. Normally, all engine oil passes
through the filter element; however, if the element becomes
restricted, a spring loaded bypass valve (~) opens as mentioned
above. DR2906
The mainoil galleries run the full length of the crankcaseand cut
into the valve lifter guide holes to supply oil at full pressureto the
lifters.
E.gi~ 3-23
Therocker armsandvalves are lubricated by an oil channelin each
pushrod. Excessoil drainsoff andreturns to the oil panthroughpas-
sagesin the cylinder headandblock.
Connectingpassages drilled in the crankcase

to permit delivery of oil
at full pressureto all crankshaftandcamshaftbearings,distributor
gear andshaft, the fuel pumppushrod, andthe timing chain.
Holesdrilled in the crankshaftcarry oit fromthe crankshaftbearingsto

the connectingrod bearings.Pistonsandcylinder walls are lubricated
by oil forced througha small notchin the bearingparting surfaceon
the connectingrod, whichregisters with the hole in the crankpinonce
everyrevolution. Piston pins are lubricated by splash.
Oil Pan
Removag DDEN)
1. Remove
oil dipstick andwithdrawoil usinga suction pump.
2. Remove
oil dipstick tube. Remove
screws,oil panandgasket.
®
Installation
[~ ~ ~] V-6 Models with ribbed aluminumoil pan.

~ Note~Thealignmentbetweenthe rear of the oil pan andrear of
the engineblockis critical. Thetwosurfacesmustbe flush to prevent
interfearenceof the flywheelhousingto enginefit. Usea straight edge
andfeederguageth checkclearenceon three oil panto flywheel hous-
ing points as shown.If clearenceis greater than 0.010in.(0,254 mm)
repeatprocedureuntil properclearenceis obtained.
1. Thoroughlycleanall gasketsealing surfaces. ApplyRTVsealer to

the front andrear of the block. Applythe sealantabout1 in. in both
directions fromeachof the four corners
E~ v-6 Modelswith ribbed aluminum oil pan. Install gasket on
block.Install oil pan.Tightenbolts to 18 ft. Ibs. (25 N.m)andnuts
17 ft. Ibs. (23 N.m)is sequence shown.
V-6 Modelswith stamped shet metaloil pans°Install gasketon block.

Install oil pan. Tighten1/4x20screwsto 80 in. Ibs. (9 N.m)and 31576
16xl 8 screwsto 165in. Ibs. (18,6 N.m).
E~] 3. Install dipstick tube fitting to pan; leavescrewloose. Orient

fitting andattachdipsticktube.Thentightenfitting screwandflare nut.
SeeTorqueSpecificationsat the endof this section for the torque
figure.
4. Fill crankcase
with engineoil.
3-24 Englne/eng
[2=2] 2. Removepumpto rear main bearing cap bolt, and remove
!pump,extensionshaft and collar.
I~ Baffle bolts have to be loosened.
:3. Disconnectpumpshaft from extension.
.4. Remove four cover attaching screws,cover, gasket, idler gear

,and drive gearandshaft.
!5. Remove
pressureregulator valve andvalve parts.
6. if the pickup screen and pipe assemblyneedreplacing, mount

the pumpin a soft-jawed vise andextract pipe from pump.IDo not
disturb the pickup screen on the pipe. This is serviced as an
assembly.
"7. Washall parts in cleaning solvent and dry using compressed

air.
47377
Inspection
Should any of the following conditions be found during inspec-

tion operations, the pumpassemblyshould be replaced.
1. Inspect pumpbodyfor cracks and excessivewear. inspect oil

pumpgears for excessive wear or damage.
2. Checkshaft for loosenessin the housing.Checkinside ot cover

for wearthat wouldpermit oil to leak past the endsof gears.
:3. Checkthe oil pickup screen for damageto screen or relief

grommet=Checkfor oil in the air chamber.
4. Checkpressureregulator valve plungerfor fit in cover.
Assembly
and Installation
1. Place drive gear and shaft in pump body.
2. Install idler gear so that smoothside of gearwill be towardthe

(:over.
3. install a newpumpto cover gasket to ensure correct end
clearanceof the gears.
4. install suction pipe and screenassemblyto cover and install

{:over and attaching screws.Tighten screwsto 6-9 ft. Ibs. (8-12
N-m),andcheckto see that shaft turns freely.
[3~ ~ if the pickup screen and pipe assembly was removed,
it shouldbe replacedwith a newpart. Lossof press fit condition
could result in an air leak and loss of oil pressure. Mountthe
pumpin a soft-jawed vise, apply sealer to endof pipe, and using
Tool J-8369tap the pipe in place with a plastic hammer.
DR2099
5. Install regulator valve plunger, spring and retainer and pin.
6. Assemble collar end of extension shaft assembly over pump

driveshaft, aligning tang of extension shaft with slot in end of
pumpdrive shaft.
7. Assemblepumpand extension shaft to rear main bearing cap,

aligning slot on top end of extension shaft drive tang on lower
end of distributor driveshaft.
8. Tighten baffle bolts.

[~ Oil pumpshould slide easily into place, if not, remove and
relocate slot or locate other problem.
9. install oil pan using new gaskets and seals. Connectoil drain
tube.
Measuring Camshaft Lobe Lift

1. Removethe valve mechanismas previously outlined.
E~ 2. Position indicator with ball socket adapter (Tool J-8520)

push rod. Makesure push rod is in the lifter socket.
3. Rotate the crankshaft slowly in the direction of rotation until the

lifter is on the heel of the camlobe. At this point, the pushrod will
be in its lowest position.
4. Set dial indicator on zero, then rotate the crankshaft slowly, or

attach an auxiliary starter switch and "bump" the engine over, /.
until the push rod is fully raised position. /
Wheneverthe engine is cranked remotely at the starter,

with a special jumper cable or other means, the distributor
primary meadshould be disconnected from the distributor coil.
D~I~
Gi Models: Remove2 wire (pink and brown) connector from
distributor.
5. Comparethe total lift recorded from the dial indicator with

specifications.
6. if camshaft readings for all lobes are within specifications,

removedial indicator assembly.
7. Install and adjust valve mechanismas outlined.
3-26 I:~ine/eng
Rear Main Bearing Oil Seal Replacernent
Care should be taken when removing the rear crankshaft
oil seal so as not to nick the crankshaft sealing surface.
1. Removeflywheel and oil pan.

[2~ 2. insert a screwdriver into the notches provided in the seal
retainer and pry the seal out. Take care not to damagethe
crankshaft sealing surface.
3. inspect chamfe~on crankshaft for grit, loose rust, and burrs.

Correct as necessary.
4. Clean seal running surface on the crankshaft with a non=

abrasive cleaner.
5. Lubricate the inner and outer diameter of newseal with engine

oH.
[~] 6. install the seal on Seal installer J-35621. Position installer

against the crankshaft. Thread the attaching screws into the
tapped holes in the crankshaft.
DR1879
7. Tighten the screws securely with a screwdriver. This will
ensure that the seal is installed squarely over the crankshaft.
8. Turn the handle until it bottoms. Remove

installer.
Oil Seal Retainer Replacement
[~ 1. Removescrews, nuts and seal retainer ~).
2. Removegasket.
3. Remove
rear crankshaft oil seal as previously stated.
DR1881
4. Clean gasket su~aces on block and seal retainer.
Whenever the seal retainer is removed, a new re~Lainer

gasket and rear crankshaft oil seal must be installed.
L~ 5. Attach gasket ® to the block. It is not necessary to use

sealant to hold the gasket in place.
6. install seal retainer, screws and nuts. Tighten screws and nuts
to 135 in. Ibs. (15,3 N-m).
7. Install oil pan. install rear crankshaft oil seal as oulIlined

previously.
8. Install flywheel.
E~i../o.~ 3-27
Crankshaft
Description
Mainbearingsare of the precision insert type and do not utilize
shims for adjustment, if clearancesare found to be excessive, a
newbearing, both upper and lower halves, will be required.
Bearingsare available in standardsize and 0.001in., 0.002 in.,
0.010in. and0.020in. (0,025, 0,051, 0,254, 0,508ram)undersize.
Selective fitting of both rod and mainbearings is necessaryin
productionin order to obtain close tolerances.For this reasonyou
mayfind one-half of a standardinsert with one-half of a 0.001in.
(0,025 ram) undersize insert which will decreasethe clearance
0.0005in. (0,0127ram) from using a fuUl standardbearing.
Whena production crankshaft cannot be precision fitted by this

method,it is then ground0.009in. (0,229 ram)undersizeon only
those mainjournals that cannotbe properly fitted. All journals
will not necessarily be groundundersize. A 0.009 in. (0,229 ram)
undersize bearing and 0.010 in. (0,254 mm)undersize bearing
maybe usedfor precision fitting in the samemanneras previ-
ously described.
If, for any reason, mainbearing caps are replaced, shim-

ming may be necessary. Laminated shims for each cap are
available for service. Shimrequirement will be determined by
bearing clearance.
inspection
in general, (except No. 1 bearing) the lower half of the bearing

showsa greater wearand the mostdistress from fatigue, if upon
inspection the lower half is suitable for use, it can be assumed
that the upperhalf is also satisfactory. If the lower half shows
evidenceof wear or damage,both upper and lower halves should
be replaced. Neverreplace one half without replacing the other
half.
To CheckCrankshaft:
a® Removemain bearing caps and connecting rod caps and

lift crankshaftout of cylinder block. Pushpistons to top
of bores.
b. Inspect the crankshaft. Number1 main bearing is ground
to 2.4484- 2.4493in. (62,1894- 62,2122ram), number
3~ 4 bearings to 2.4481- 2.4490in. (62,1817- 62,2046
ram), number5 bearing to 2.4479- 2.4488in. (62,1767
62,1995mm),and crankpin journals are groundto 2.0988
- 2.0998in. (53,310- 53,335ram).
3-28 E~
These dimensions should be checked with a micrometer for
out-of-round, taper or undersize. If the journals exceed0.001 in.
(0,025 mm) out-of-round or taper, the crankshaft should
replaced or reconditioned to an undersize figure that will enable
the installation of undersize precision type bearings.
The crankshaft should also be checkedfor runout. To perform this

operation, support the crankshaft at the front and rear main
bearing journals in "V" blocks, and indicate the runout of both the
rear intermediate and front intermediate journals, using a dial
indicator. The runout limit of each of these journals is 0.002 in.
(0,051 mm). If the runout exceeds 0.002 in. (0,051 met),
crankshaft must be repaired or replaced.
]’o obtain the mostaccurate results with Plastigage (or its equiva-
lent), a wax-like plastic material which will compress evenly
between the bearing and journal surfaces without damaging
either surface, certain precautions should be observed. With the
engine out of the boat and upside down, the crankshaft will rest
on the upper bearings and the total clearance can be measured
between the lower bearing and journal.
[~ To ensure the proper seating of the crankshaft, all bearing

cap bolts should be at their specified torque. In addition, prepara-
tory to checking fit of bearings, the surface of the crankshaft
journal and bearing should be wiped clean of oil.
1. With the oil pan and oim pumpremoved, and starting with the
rear main bearing, remove bearing cap. (Note: Wipe oil from
iournal and bearing cap before applying Plastigage materi,~l.)
E~ 2. Place a piece of gauging plastic ~) the full width of the

bearing (parallel to the crankshaft) on the journal
Do not rotate the crankshaft while the gauging plastic is 47397
3. Install the bearing cap and evenly tighten the retaining bolts to
specifications.

found adhering to either the bearing shell or journal.
E2--~ 5. On the edge of gauging plastic envelope there is a
graduated scale which is measuredin thousandths of an inch.
Without removing the gauging plastic, measure its compressed
width (at the widest point) with the graduations on the gauging
plastic envelope.
47407
E!lgine/eng 3-29
round journal; 0.001 in. max. (0,025 ram) be sure to fit it to the
maximum diameter of the journal, if the bearing is fitted to the
minimum diameter and the journal is out-of-round 0.001 in.
(0,025 mm), interference between the bearing and journal will
result in rapid bearing failure. If the flattened gauging plastic
tapers toward the middle or ends, there is a difference in clear-
ance indicating taper, low spot or other irregularity of the bearing
or journal. Be sure to measurethe journal with a micrometerif the
flattened gauging plastic indicates more than 0.001 in. (0,025
mm)difference.
6. if the bearing clearance is within specifications, the bearing

insert is satisfactory. If the clearanceis not within specifications,
replace the insert. Always replace both upper and lower insert as
a unit.
If a newbearing cap is being installed and clearanceis less

than 0.001 in. (0,025 mm),inspect for burrs and nicks; if none are
found then install shims as required.
7. A standard size 0.001 in. or 0.002 in. (0,025 or 0,051 mm)

undersize bearing mayproducethe proper clearance, if not, it will
be necessary to regrind the crankshaft journal for use with the
next undersize bearing.
8. Proceed to the next bearing. After all bearings have been

drag.
[~ 9. Measure crankshaft end play (see Specifications)

forcing the crankshaft to the extreme front position. Measureat
the front end of the rear main bearing with a feeler gauge.
10. install a newrear main bearing oil seal in the cylinder block
and main bearing cap.
Main Bearing Replacement
1. Install a mainbearing removingand installing tool in oil hole in

crankshaft journal. 47417
[~ if such a tool is not available, a cotter pin maybe bent as

required to do the job.
2. Rotate the crankshaft clockwise as viewed from the front of

engine. This will roll upper bearing out of block.
3. Oil new selected size upper bearing and insert plain (unnotc-
hed) end between crankshaft and indented or notched side of
block. Rotate the bearing into place, and removetool from oil hole
in crankshaft journal.
3-30 E~ine~ng
4. Oil newlower bearing and install in bearing cap.
!5. install main bearing cap with arrows pointing toward front of
engine.
6. Tighten main bearing cap bolts to specifications.
Connecting Rod Bearing Replacement

Connecting rod bearings are of the precision insert type and do
not utilize shims for adjustment. DO NOT FILE RODSOR ROD
lAPS. if clearances are found to be excessive a newbearing will
be required. Bearings are available in standard size and 0.001 in.
(0,025 ram) undersize for use with standard size crankshafts.
11. With oiJ pan and oil pumpremoved, removethe connecting rod
cap and bearing.
;!. inspect the bearing for evidence of wear or damage.(Be;arings

showing the above should not be installed.)
3. Wipe the bearings and crankpin clean of oil.
4. Measurethe crankpin for out-of-round or taper with a microme-

ter. If not within specifications, replace or recondition the crank-
shaft. If within specifications and a newbearing is to be insltalled,
measure the maximumdiameter of the crankpin to determine
new bearing size required.
5. if within specifications, measurenew or used bearing clear-

ances with the Plastigage material or its equivalent.
If a bearing is being fitted to an out-of-round crankpin, be

sure to fit it to the maximumdiameter of the crankpin. If the
bearing is fitted to the minimumdiameter and the crankpin is
out-of-round 0.001 in. (0,025 ram), interference between the
bearing and crankpin will result in rapid bearing failure.
a. Place a piece of gauging plastic the full width of the

crankpin parallel to the crankshaft. (Note: Surfaces must
be free from oil.)
b. Install the bearing in the connecting rod and cap.
c. Install the bearing cap and evenly tighten nuts to specifi-

cations.
L~vQ_~Do not turn the crankshaft with the gauging plastic

installed.
d. Removethe bearing cap and using the scale on the

gauging plastic envelope, measurethe gauging plastic
width at the widest point.
Englr~/eng 3-31
6. if the clearanceexceedsspecifications select a new, correct size
bearing and remeasure the clearance.
7. Coat the bearing surface with oil, install the rod cap and tighten
nut to specifications.
8. Whenall connecting rod bearings have been installed tap each

rod lightly (parallel to the crankpin) to makesure they have
clearance.
9. Measurea[I connecting rod side clearances (see Specifica-

tions at end of this section), betweenconnecting rod caps. 47427
Piston, Ring and Connecting Rod

Piston and Rod Removal
1. With oil pan, oil pumpand cylinder head removed, use a ridge
reamer to remove any ridge and/or deposits from the upper end
of the cylinder bore.
Before ridge and/or deposits are removed, turn crankshaft

until piston is at the bottom of stroke and place a cloth on top of
piston to collect the cuttings. After ridge and/or deposits are
removed, turn crankshaft until piston is at top of stroke and
removecloth and cuttings. /
J 5239
2. Inspect connecting rods and connecting rod caps for cylinder

J 5239--
identification. ’If necessarymark them.
[~ 3. Removeconnecting rod cap and install tool J-5239 on

studs. Push connecting rod and piston assembly out of top of
cylinder block.

disconnect some of the connecting rod and piston assemblies
DR3792
and push them out of the cylinder.
Piston and Rod Disassembly
1. Removeconnecting rod bearings from connecting rods and

cap.
If connecting rod bearings are being reused, pmacethem in

a rack so they maybe reinstalled in their original rod and cap.
2. Removepiston rings by expanding them and sliding them off

the pistons. Ring expandertools are available from Iocam automo-
tive stores.
3. Using tools J-24086-20(~) and J-24086-8 ~), peaceconnect-

ing rod and piston assembly in an arbor press with piston on
support, then using remover, press piston pin out of connecting
rod and piston.
4. RemoveassembJy from arbor press and remove tools, piston

pin, connecting rod and piston.
3-32 ~13s
Engme/eng
5. Clean varnish from piston skirts and pins with a cleaning
solvent. DO NOTWIREBRUSHTHEPISTONSKIRT. Clean the ring
grooves with a groove cleaner, and makesure oil ring holes and
slots are dean.
6. inspect the piston for cracked ring Uands,skirts or pin bosses,

wavy worn ring lands, scuffed or damagedskirts, or eroded areas
at top of the piston. Replace pistons that are damaged or
7. Check fit of used piston pins. Use a dial bore gauge or

tenescoping snap gaugefor the bore and a micrometer for the pin.
Wearlimit on piston is production clearance plug 0.001 in. (0,025
~.
rnm). Replace piston and pin assemblyif wear is excessiw,

either pin boss whencoated with light engine oil and at 60° F.
Higher or lower temperatures will cause false indications.
Piston pins are matchedfit to the piston and are not available
knock or tapping until after prolonged use, and in such cases a
new piston and pin assembly should be installed.

] 94137
1. Lubricate piston pin holes in piston and connecting rod to

~4~ 2. Use J-24086-20, J-24086-9 and guide tools. Place connect-
ing rod in piston and hoRdin place with piston pin guide ~ and
piston pin ~). Place assemblyon fixture and support assembJy(~.
L-~ 3. Using piston pin installer, J-24086-9 (~), press the piston
pin into the piston and connecting rod.
The piston pin installer is a variable insertion length tool.

The insertion length is varied by rotating the hub on the shaft
muchlike adjusting a micrometer. An alphanumeric scale is used
to determine the desired length for a given piston pin assembly.
After installer hub bottoms on support assembly, do not exceed
5000 PSi (34475 kPa) pressure, as this could cause structural
damageto the tool.
4. Removepiston and connecting rod assembly from tool and

check piston for freedom of movementon piston pin.
94138
E~glne/eng 3-33
Piston Rings
Piston rings are furnished in standard sizes as well as 0.030 in.

(0,762 mm)oversize.
Oil control rings consist of two segments(rails) and a spacer.
Compressionrings are the deep section twist type, 3~2 in. (2,38
mm) wide.
This type compression ring takes it name, twist type, from its
installed position which is cocked or twisted, it assumesand
section.
All compression rings are marked with the metters "GM"

cast in the upper side of the ring. Wheninstalling compression
piston.
1. Select rings comparablein size to the piston being used.
l~ it is important that each ring be fitted to its individual

cylinder for proper gap spacing, and to its individual piston and
groove for proper groove clearance.
2. Slip the compressionring in the cylinder bore; then, using the

head of a piston, press the ring downinto the cylinder bore about
1/4 in. (6,5 ram).
the cylinder wal~s.
EEl 3. Checkthe space or gap betweenthe ends of the ring with a

feeler gauge, if the gap between the ends of the rings is below
specifications, removethe ring and try another for fit. Fit eachring
separately to the cylinder in which it is going to be used.
4. New pistons, rings and cylinder bores wear considerably

greater than 1/32 in. (0,792 ram}.
86OO48
5. Carefully removeall particles of carbon from the ring groove in

the piston and inspect the grooves carefully for burrs and nicks
that might cause the rings to hang up.
[2-~ 6. Slip the outer surface of the top and second compression
ring into their respective piston ring groove, and roll the ring
entirely around the groove to makesure the ring is free and does
not bind in the groove at any point, if binding occurs, the cause
should be determined and removed by carefully dressing with a
1Fine cut file. However,if the binding is causedby a distorted ring,
install a newring.
Piston Ring Installation
’1. install the oil ring spacer in the oil ring groove, and insert
antirotation tang in oil hole. Hold spacer ends butted, and install 10755
steel rail on top side of spacer. Position gap at least one inch (2,54
cm) to left of spacer gap, then install secondrail on lower ,;ide of
spacer. Position gap at least one inch to right of spacer gap.
2. Flex the oil ring assemblyin its groove to makesure ring is free
and doesnot bind in the groove at any point. If binding occurs, the
cause should be determined and removed by carefully dressing
with a fine cut file. However, if the binding is caused by a
:3. install second compression ring, then top compression ring

and properly locate gaps.
[~] 4. Proper clearance of the piston ring in its piston ring groove
is very important in maintaining engine performance and in
preventing excessive oil consumption. Therefore, when fitting
new rings, the clearance between the top and bottom surfaces of
5. The upper compression ring should be fitted so that the

clearance is 0.0012 in. to 0.0032 in. (0,0304 to 0,0813 ram).
Clearance of lower compression ring is also 0.0012 in. to 0.0032
in. (0,0304 to 0,0813 ram).
6. Assemblethe rings to the pistons as they are fitted, and makea 860050
procedure given above.
Piston and RodInstallation
oil.
2. With bearing caps removed, install tool J-5239 on bearing cap

bolts.
3. Instalm each piston in its respective bore, using tool J-5239 on

each assembly. The side of the piston with the cast depression in
the head should be to the front of the cylinder block and the
connecting rod bearing tang slots facing side opposite camshaft.
Guide the connecting rod into place on the crankshaft journals
with the long detail of tool J-5239.
I’nglne/eng 3-35
[~ Check position of ring end caps. They must not align with
each other or the oil ring.
El 4. Use tool J-8037 (~) to compressthe piston rings.
5. Install bearing caps and check the bearing clearance as de-

scribed previously.
Cylinder Block
inspection
47437
1. Checkthe cylinder block for cracks in the cylinder walls, water

[~ 2. Checkthe cylinder walls for taper, out-of-round or exces-

sive ridge at top of ring travel. This should be done with a Dial
Indicator J-8087. Set the gauge so that the thrust pin must be
forced in about 1/4 in. (6,5 mm)to enter gaugein cylinder bore.
Center gauge in cylinder, and turn dial to "0." Carefully work
gauge up and down cylinder to determine the out-of-round
condition, if cylinders were found to have more than 0.002 in.
(0,051 mm)out-of-round, boring will be necessary.
Cylinder Conditioning
The performance of the following operations is contingent upon

if the cylinder block inspection indicated that the block was

suitable for continued use except for out-of-round or tapered 860053
cylinders, they can be conditioned by honing or boring and

honing.
if the cylinders were found to have less than 0.005 in. (0,127 ram)
0.001 in. (0,025 mm)oversize pistons. A cylinder bore of less than
0.005 in. (0,127 mm)wear or taper maynot entirely clean up when
fitted to a 0.001 in. (0,025 mm)oversize piston, if it is desired
entirely clean up the bore in these cases, it will be necessary to
rebore for an oversize piston, if more than 0.005 in. (0,127 mm)
taper or wear exists, they should be bored and honed to the
smallest oversize that will permit complete resurfacing of all
cylinders.
Cylinder Boring
1. Before using any type boring bar, the top of the cylinder block
should be filed off to remove any dirt or burrs. This is very
important. Otherwise, the boring bar may be tilted which would
crankshaft.
3-36 E.oi~,/~
2. Place the honeinto a cylinder bore, and expandthe stone~3until
the hone can just be turned by hand. Connecta 1/2 in. (1,27 cm)
electric drill to the hone, and drive hone at drill speed while
moving hone up and down entire length of cylinder until hone
begins to run free. During this operation, a liberal amount of
kerosene should be used as a cutting fluid to keep the stones of
the hone cmean. Move hone slowly up and down with rough
stones, but movehone up and down rapidly enoughwith the fine
stones to producea final bore finish of very fine surface scratches
in a crosshatch pattern of approximately 45° to 65° included
angle. The marks should be clean but not sharp, and free from
embeddedparticles or torn or folded metal.
3. Expand the stones against the cylinder bore, and repeat the

should be thoroughly cmeanedand the piston selected for the
individual cymindercheckedfor correct fit.
Thoroughly clean cylinder bores with soap and hot ,water

to removeall grit particles.
Piston Selection
1 CheckUSEDpiston to cylinder bore clearance as follows.:
a. Measurethe "Cylinder Bore Diameter" with a tele,,=cope

gauge21/2 in. (64 ram) from top of cylinder bore.
b. Measurethe "Piston Diameter" (at skirt across centerline

of piston pin).
c. Subtract piston diameter from cylinder bore diameter to

determine "Piston to Bore Clearance."
d. Calculate piston to bore clearance and determine if

piston to bore clearance is in the acceptable range.
2. If used piston is not acceptable, check if a new piston can be

selected to fit cylinder bore within the acceptable range.
3. if cylinder bore must be reconditioned, measurenew piston

diameter (across centerline of piston pin), then hone cylinder bore
to correct clearance (preferable range}.
4. Markthe piston to identify the cylinder for which it was fitted.

[~ Handle the pistons with care, and do not attempt to force
them through the cylinder until the cylinder has been bored to
correct size as this type piston can be distorted through careless
handling.
5. Thoroughly clean the cylinder bores with hot water and soap.
Scrub well with a stiff bristle brush and rinse thoroughly with hot
water. It is extremely essential that a good clean operation be
performed. If any of the abrasive material is allowed to remain in
the cylinder bores, it will rapidly wear the newrings and cylinder
bores in addition to the bearings lubricated by the contaminated
oil. The bores should be swabbedseveral times with light engine
oil and a clean cloth then wiped with a clean dry cloth. Cylinders
should not be cleaned with kerosene or gasoline. Clean the
remainder of the cylinder block to remove the excess material
spread during the honing operation.
Circulating Pump
Description
The Volvo Penta circulating pumpis manufactured specially for

marine use. it is serviced only as an assembly. Do not replace
with an automotive circulating pump.
inspection
1. Removealternator and power steering belts.
2. Grasp circulating pumppulley and check end and side play.

Turn pulley to check for drag.
3. Look for water leaking from indicator hole beneath pumpshaft

behind pulley. Replacepumpif play, drag, or leakage are evident.
Removaland Installation
1. Drain water from block and disconnect water hose from

circulating pump.
2. Removepulley. Removecirculating pump bolts, pump and

gaskets.
3. Use new pumpto block gaskets and sealer. Install new pump
assembly on cylinder block and tighten bolts as specified.
4. Install pulley, install alternator and powersteering belts, then

adjust tension.
5. Install hose to circulating pump.
6. Lake or tank test unit and checkfor leaks.
25929
3-38 Engff~e/eng
Front Engine Mounts
Removal
[3 1. Removetwo lag screws ~) and washers from mounts.
L~ 2. Lift enginewith a hoist capableof lifting at least 1500 lb.

(680 kg) to allow removalof front mountand bracket.
[~ 3. Remove three mount screws and lock washers ®, Note

screw lengths and location.
25917
[3 [~ Prior to disassembly of front mount assembly, mea-
sure distance and record measurement between large washer
and flat on upper mount bracket.
Disassembly
[3 1. Removethree Iocknuts © and engine mount bracket ~)

from mount bolt while holding bolt secure with socket (~).
L=~ 2. Removetwo washers (~ and engine mount bolt ~)from

mount.
11980
Reassembly
E~ 1. Place small washer (~) on mount bolt and insert bolt

through mount. Install large washer and secure with nut (i).
Tighten to 60-75 ft. Ibs. (81-102 N-m).
2. install Upper inner nut and place engine mount bracket @

on engine mount bolt.
Measuredistance between large washer and fiat on upper

mount bracket. Adjust distance to recorded measurement.
3. install lock washerand top nut. Tighten nut to 100-120ft. Ibs. 11979
{136-163 N.m).
installation
DE] 1. Spray the engine mount screw threads with Loctite primer
or equivalent and allow to air dry. AppmyLoctite or equivalent to
the screws. Attach engine mount assembly to engine with three
screws and washers. Tighten to 32-40 ft. Ibs. (43-54 N-m).
EI~ 2. install lag screws and tighten securely.
1197~
~1983
Height Adjustment
[~ 1. To change engine height, tighten or loosen nuts (~) and
as required.
L~ 2. Lift enginewith a hoist capableof lifting at least 1500|b.

(680 kg), Position engineat desired height,
El 3. After setting mount position, turn upper inner nut ~) up

against underside of engine bracket and hold nut with a wrench.
Tighten top nut ~) to 100-120 ft. Ibs. (136-163 N-m).
2953
Any large adjustments to engine height should be fon-
lowed by a check of engine aRignment. Failure to check alignment
could result in rapid engine coupler failure. See Drive Removal
and Installation section of the Drive Unit/Transom Shield Work-
shop Manual for alignment procedures.
High-Rise Exhaust Elbow Repiacernent

Removal
[~ 1. Loosen two damps securing upper hose to elbow. Lubri-

cate inside of hose with a soapy water solution. 34719
~] 2. Starboard Elbow: Removecircuit breaker bracket © and

set aside. Removefour screws, flat washers, and lock washers
mounting high-rise elbow.
[~ 3. Use a soft hammerto free elbow from manifold. Use

a twisting motion to pull elbow from hose. Removeand discard
the elbow gasket.
Installation
1. Thoroughly clean manifold gasket surface. Apply Gasket Seal-

ing Compoundto both sides of a new manifold gasket and place it
on the exhaust manifold.
[~ [~ 2. Lubricate the inside of the exhaust hose with a soapy

water solution, insert the high-rise elbow into the hose with a
twisting motion, and push it into hose as far as it wiIB goo
[~ 3. Position elbow on manifold. Secure eabows and brackets

with four screws, fiat washers, and lock washers. Tighten screws
to 12-18 ft. Ibs. (16-24 N.m). Starboard Elbow: InstaBI circuit
breaker bracket ©.
[~ /~ 4. Slide clamps ® up onto hose and position them in the 34718
two surface channels. Tighten clampssecurely.
Z~ Safety Related 3-40

32371 32374
Exhaust Hose and intermediate Pipe

Replacement
Removal
[8~ 1. Loosen eight clamps that secure the upper @and lower (~
exhaust hoses.
2. Lubricate inside of lower hose with a soapy water" solu-

tion, and slide lower hose down onto exhaust Y-pipe.
32375
L~ 3. Twist intermediate pipe out of upper hose. Lubricate
inside of upper hose if necessary to ease removal.
4. Slide upper hose off high-rise elbow° Slide lower hose off
exhaust Y-pipe.
installation
1. Lubricate inside diameter of 3.5 in. (8,89 cm) i.D. lower

hose with a soapy water solution. Slide it all the way onto the
exhaust Y-pipe.
[~ [~ The inside diameter of both the upper and lower

hoses has a step (D 1.5 in. (3,81 cm) from one end. The stepped
end of the hose must face the intermediate pipe wheninstalled.
2. Slide hose onto high-rise elbow untiU it seats.
if hose is not properly positioned, it will not completely

engagethe high-rise elbow or allow secure attachment.
[~ 3. With a twisting motion, insert intermediate pipe all the

way into the upper hose. Align lower end of pipe with exhaust
Y-pipe, then slide lower hose up until it’s halfway onto the
intermediate pipe. 32370
[8-7 ~ 4. Place four No. 68 clamps on upper hose. Plac|. = four

No. 64 clamps on lower hose. Position clamps in channels and
tighten securely.
32366
Exhaust(Flapper) Valve Replacement
SX
Models
Removal
1. Removethe intermediate exhaust pipe following the procedure

under Exhaust Hose and Intermediate Pipe Replacement.
[~ 2. Slide the lower hose down far enoughto expose the valve
pivot pin. Hold the valve while pulling out the pin, then lift out the
valve.
32367
3. Inspect the two rubber bushings inside the pipe. Replace

them if necessary.
lnstaBation
[~ 1. If installing new rubber bushings, apply Scotch Grip
Rubber Adhesive to outside of tips, and insert into inside of
exhaust pipe.
[~ 2. Position valve with longest lip pointing down, and insert

into pipe. Pushpivot pin through bushings and valve until pin end
is flush with outside of pipe. Checkexhaust valve for freedom of 32368
movement.
if valve is not positioned properly (long lip down}, it will

restrict exhaust flow and fail to prevent water backing up into
engine. Boat performance would be adversely affected, and
engine may suffer water damage.
3. Install intermediate pipe following procedure under Exhaust

Hose and Pipe Replacement.
Engine Coupler Replacement- SX Models

32369
Removal
1. Removeengine from boat.
if coupler is being replaced due to coupler failure (rubber

hub of splined hub), check engine alignment after installing new
coupler. See Drive Removaland Instal|ation section of the Drive
Unit/Transom Shield WorkshopManual.
2. Disconnect all wires, lines and connectors from bellhousing.
I~] [~ 3. Remove screws securing bellhousing cover, and

26034
slide cover out.
19085
3-42 Englne/eng
[6~ 4. Pull drain hose out of bellhousing.
[7~ 5. Unscrewbolts and nuts retaining bellhousing. Disconnect

ground wires. Removepower steering cooler bracket.
6. Removebeilhousing from engine block.

¯ v- -
[3 7. Unscrew six nuts securing coupler and remove coupler
from studs.
8. Removeold gasket from bellhousing cover. Clean gasket

surface thoroughly. 19842
Installation
[9~ 1. Install coupler and secure with six Iocknuts. Use a suitable
adaptor and tighten to 40-45 ft. Ibs. (54-61 N.m).
EEl 2. Install beHhousing and attach power steering c, ooler.

Tighten nuts and bolts to 32-40 ft. Ibs. (43-54 N-m). Attach ground
wires and tighten nuts to 15-20 ft. Ibs. (20-27 N-m).
3. Push drain hose into bellhousing.
4. Apply Gasket Sealing Compoundto both sides of a new

bellhousing gasket and position it on cover.
[~ 5. Clean seven self-tapping screws with a wire brush. Install

betJhousJngcover and screws. Tighten to 60-84 in. Ibs. (7-9 N-m).
6. Connectall wires, lines and connectors to bellhousing.
7. install enginein boat.
6712
6714
GeneralSpecifications- 4.3 GL, GS, andGi __ _ _
Type - No. of Cylinder ..................................... 90" - V-6
Bore and Stroke ..................... 4.00 x 3.480in, (101.6 x 88.39 mm)
Piston Displacement ....................... 262CubicInches(4.3 liters)
Cylinder Numbers - Front to Rear
Starboard ................................................ 2-4-6
Port .................................................... 1-3-5
Firing Order ........................................... 1-6-5-4-3-2
CompressionRatio .......................................... 9.3:1
Water TemperatureControf ............................... Thermostat
Thermostat Opens at ........................................ 160° F
Alternator Belt Adjustment.............. 1,4"-1/2"flex (20- 25kg, 44- 55lbs)
Full throttle operating range, GL...................... 4200 = 4600 RPM
Full Throttle Operating Range,GS, Gi ...................... 4400 - 4800
GeneralSpecifications
- 4.3 GL,GS,andGi *
Type - No. of Cylinder ..................................... 90° - V-6
Bore and Stroke ..................... 4.00 x 3.480in, (101.6 x 88.39mm)
Piston Displacement ....................... 262CubicInches(4.3 liters)
Starboard ................................................ 2-4-6
Port .................................................... 1-3-5
Firing Order ........................................... 1-6-5-4-3-2
Compression Ratio .......................................... 9.4:1
Water TemperatureControl ............................... Thermostat
Thermostat Opensat ........................................ 160° F
Alternator Bett Adjustment.............. 1A"-1/£’flex (20- 25kg, 44- 55Ibs)
Full throttle operating range, GL...................... 4200 - 4600 RPM
Full Throttle Operating Range,GS, Gi ...................... 4400- 4800
GeneralSpecifications
- 5.7 GL,Gi
Type - No of Cylinders ..................................... 90° - V-8
Bore and Stroke .................... 4.000 x 3.480 in. (101.6 x 88.39mm)
Piston Displacement ....................... 350Cubicinches(5.7 liters)
Starboard .............................................. 2-4-6-8
Port .................................................. 1-3-5-7
Firing Order ........................................ 1-8-4-3-6-5-7-2
Compression Ratio .......................................... 9.3:1
Water TemperatureControl ............................... Thermostat
Thermostat opens at ........................................ 160°F
Alternator Belt Adjustment.............. 1/4"-1/2"
flex (20- 25kg, 44- 55Ibs)
Full Throttle Operating Range........................ 4200 - 4600 RPM
Pistons:
Production Clearance ............................................. 0.0007 - 0.0017 in.
Service .......................................................... 0.0027 in. Max.
Piston Rings, Compression:
Production Groove Clearance
Top .................................................. 0.0012 - 0.0032 in.
2rid .................................................. 0.0012 - 0.0032 in.
Service ..................................................... + 0.001 in.
Gap
Top .................................................... 0.010 - 0.020 in.
2nd .................................................... 0.010 - 0.025 in.
Service ..................................................... + 0.010 in.
Oil Rings:
Production Groove Clearance ..................................... 0.002 - 0.007 in. Max,
Service .............................................................. + 0.001 in.
Production Gap .................................................... 0.015 - 0.055 in.
Service .............................................................. + 0,010 in.
Piston Pins:
Diameter ....................................................... 0.9270 - 0.9273 in.
Production Clearance ............................................. 0.00025= 0.00035in.
Service ............................................................ 0.001 in. Max.
Fit in Rod .............................................. 0.008 - 0~.0016in. Interference
Connecting Rods:
Bearing Clearance, Production ...................................... 0.0013 - 0.0035 in,
Service .......................................................... 0.0030 in. Max.
Side Clearance .................................................... 0.008 - 0,014 in.
Crankshaft:
End Play ......................................................... 0.002 - 0.006 in.
Main Journal Diameter
No. 1 V-6 and V-8 ........................................ 2.4484- 2.4493 in.
No 2, 3 V-6, No. 2, 3, 4 V=8 ................................. 2.4481 - 2.4490 in.
No 4 V-6, No. 5 V-8 ....................................... 2.4479 - 2.4488 in.
Taper, Production ................................................... 0.0002 in. Max.
Service ............................................................ 0.001 in. Max.
Out-of-Round, Production ............................................. 0.0002 in. Max.
Service ............................................................ 0.001 in. Max.
Main Bearing CJlearance, Production
No. 1 V-6 and V-8 ........................................ 0.0008 - 0.0020 in.
No 2, 3 V-6, No. 2, 3, 4 V-8 ................................. 0.0011 - 0.0023 in.
No 4 V=8, No. 5 V-8 ....................................... 0.0017 - 0.0032 in.
Service
No. 1 V-6 and V-8 ........................................ 0.001 - 0.0015in.
No 2, 3 V-6, No. 2, 3, 4 V-8 ................................. 0.001 - 0.0025in.
No 4 V-6, No. 5 V-8 ...................................... 0.0025 - 0.0035in.
Crankpin Diameter ................................................ 2.0988 - 2.0998in.
Taper
Production ............................................ 0.005 in. Max.
Service .............................................. 0.001 in. Max.
Out-of-Round, Production ............................................. 0.0005 in. Max.
Service ........................................................... 0.001 in. Max.
Engine/eng 3-45
Engine Specifications - Continued
Camsl-~ft:
Camshaft EndPlay........................................... 0.004 - 0.012 in. (0,101 - 0,304 mm
Camshaft Bearing Journal Diameter ........ 1.8682- 1.8692 in. (47,452 - 47,477 mm
Camshaft Run-out .................................................................. 0.0015 in. (0,0381 mm
LobeLift ................................................................... V-6 intake 0.234 in. (5,943 mm
V-6 Exhaust 0.2576 in (0,527 mm
V-8 intake 0.269 in (6,832 mm
V-8 Exhaust 0.276 in (7,010 mm
Valve System:
Lifter Type..................................................................................................... Hydraulic
Rocker ArmRatio................................................................................................ 1.5:1
ValveLashV-6.................................................................................... Not Adjustable
ValveLashV-8.................................................................................. Zero + One Turn
ValveFaceAngle................................................................................................... 45°
ValveSeatAngle................................................................................................... °46
Valve Guide Clearance:
IntakeandExhaust...................................... 0.001 - 0.0027 in (0,0254 - 0,0685 ram)
MaxServiceClearance,Exhaust............................................ +0.002 in (0,0508 mm)
MaxServiceClearance,Intake .............................................. +0.001 in (0,0254 mm)
Valve Seat Width
Intake.............................................................. 1/32 to 1/16 in (O,7937 - 0,1587 ram)
Exhaust ........................................................... 1/16 to 3/32 in (0,1587 - 0,2381 mm)
ValveSpringLength ................................................................... 2.03 in (51,562 mm)
Valve Spring Pressure
mb@in. (kg @mm}........................................... 76-84 @ 1.70 (34,5 - 38,1 @ 43,18)
Ib @in. (kg @mm)............................................ 194-206 @ 1.25 (88-93.4 @ 31.75)
EngineLubrication:
Oil Pump Type...................................................................................................... Gear
Crankcase Capacity - quarts (liters)
4.3 GL,GS,Gi .......................................... 4 qts., 4.5 w/filter (3,78 lit., 4,26 w/filter)
5.7Gi.......................................................... 5 qts., 6 w/filter (4,73 lit., 5,68 w/filter)
Oil Pressure,warmengine..................... 15-30 psi (1,055-2,109 kp/cm =} @ 800 RPM
40-60 psi (2,812-4.218 kp/cm =) @ 2000 RPM
Recommended Oil Grade:

SG Service - GM Spec 6094M
32° F (0° C) andabove................................................................................... SAE 30
0° F (-18° C) to 32° F (0° C) ................................................................. SAE 20W-20
-0° F (-18°C)............................................................................................... SAE lOW
WerecommendDuraPlusTM Synthetic Motor Oil, which is specially formulated for heavy duty marine
use and ideaRfor Volvo Pentaengines. It provides better anti-wear qualities, especially during long high
speedoperation. In addition, it neutralizes acids causedin internal combustionengines, offers superior
corrosion protection, and is formulated to offer better resistance to oxidation and high temperature
sludge formation.
Recommended
Fuel............................................................ See General Information Section
SCREW FT. LBS IN. LBS. N-m

SiZE
No. 6 7- 10 0,.8- 1
No. 10 2-3 ;!5-35 :3-4
No. 12 3-4 35-45 ,4-5
V4 5- 7 60 - 80 7- 9
sAs 10- 12 1;!0- 140 14- 16
% 18 - 20 2;!0 - 240 2,4 - 27
Use a reliable torque wrench to tighten the parts listed to prevent straining or distorting the parts or
friction which prevents accurate measurement of tightness. It is important that these torque specifica-
Balance Shaft Driven Gear ~’

15 +35 °20 +35
Balance Shaft Retainer - 120 14
Camshaft Sprocket 21 - 28
Camshaft thrust Plate V-6 - 105 11,g
Circulating Pump 30 - 41
Coil Clamp - 7-10 0,7g-1,13
Crankshaft Oil Seal Retainer - 135 15,3
Dipstick TubeFitting 15-18 - 20-24
Distributor Clamp 20 - 27
Flywheel Bellhousing 32-40 - 43-54
Flywheel Cover - 60-84 7-9
Front Mount to Engine 32-40 - 43-54
High Rise Elbow to Manifold 12-18 - 16-24
Lift Bracket 15-29 - 20-39
Oil Filter BypassValve 20 - 27
Oil Pan (1/4 × 20) - 80 9
Oil Pan (5/16 × 18) - 165 18,6
Oil PumpCover 6-9 - 8-12
Oil Seal Retainer 135 15,3
Power Steering PumpBracket 26-30 - 35-41
Rocker Arm V-6 4O 54
Rocker Arm Cover 90 10
Raw-water Pump Bracket 30 41
Timing Chain Cover 80 9
TorqueSpecifications - (Cont.)
[ FT. LB$.~ (iN. LBS.
Camshaft Sprocket 21 28
Connecting Rod Cap 45 60
Crankshaft Oil Seal Retainer - 135 15,3
Exhaust Manifold 20-26 - 27-35
Flame Arrestor - 30-40 3,4-4,5
Flare - Dipstick Tube 15-18 20-24
Flywheel Belmhousing 32-40 - 43-54
Front Mount Top 100-120 - 136-163
Oil Pan (5/16 x 18) - 165 18,6
Oil Withdrawal Tube to Elbow 15-18 - 20-24
Power Steering Bracket 13-15 - 18-20
Cylinder Head
Step 1 25 - 34
Step 2 45 - 61
Step 3 65 - 88
Harmonic Balancer (7/16 x 20) 55-62 - 75-84
High-Rise Elbow 12-18 - 16-24
Front Mount 60-75 81-102
intake Manifo0d 30 41
Main Bearing Cap
Outer Bolts on #2, #3, and #4 Caps 7O 95
All Other Bolts 80 110
Oil Pump 65 90
RemoteOil Filter Adaptor (to block) 20-25 27-34
Balance Shaft Drive Gear 12 18

Flame Arrestor - 65-80 7-9
Power Steering PumpBracket 13-15 - 18-20
Spark Plugs 22 - 30
Oil Filter OneTurn After Contact
Oil Pan Drain Retainer 15-18 - 20-24
Oil Pressure Sender 10-14 - 14-19
Oil Pressure Sender Adaptor 10-14 14-19
Water Temperature Sender 18-22 - 24-30
3-48 Engine/eng
Section4
5.0 and 5.8 FL

Table of Contents
Circulating PumpReplacement........................... 4-6

Core Plugs ........................................... 4-23
Crankshaft Rear Oil Seal ............................... 4-18
Cylinder Head .......................................... 4-9
Diagnosis and Testing
Camshaft Lobe Lift ................................... 4-24
Compression Test ................................... 4-25
PCVSystem .......................................... 4-26
Engine Coupler Replacement ........................... 4-32
Engine Specifications .................................. 4-36
Exhaust (Flapper) Valve Replacement.................... 4-31
Exhaust Hose and Intermediate Pipe Replacement......... 4-30
Exhaust Manifold Replacement ...........................
Front Cover and Timing Chain ...........................
4-5
4-12 i
Front Engine Mounts ................................... 4-27
Height Adjustment ................................... 4-29
Front Oil Seal ......................................... 4-14
High-Rise Exhaust Elbow Replacement ................... 4-29
Intake Manifold ......................................... 4-3
Oil Pan ............................................... 4-15
Oil Pump............................................. 4-16
Torque Specifications .................................. 4-34
Valve Clearance Check ................................. 4-21
Valve Lifter ........................................... 4-22
Valve Rocker Arm and Cover ............................ 4-19
Valve Spring, Retainer and Stem Seal .................... 4-11
/~ Safety Warnings
Beforeworkingon anypart of the engine,readthe sectioncalled Safetyat

the endof this manual.
Unlessinstructed otherwise, alwaysdisconnectthe battery cables from

the battery beforeworkingon electrical system1o preventpossiblesparks
or arcing in the enginecompartment.
Beforestarting engineafter repair or maintenance

procedures,alwaysmake
sure enginecompartment
is free of fuel vaporsto preventpossiblefire and
explosion.
When workingon an enginethat is runningor being cranked,use extreme

care to avoidgetting hands,fingers or clothing caughtin the alternator,
powersteering pump,raw-waterpumpandcirculating pumpbelts, pulleys
andother movingparts.
Materials Required
Cleaning somvent
DuraPlus Synthetic Motor Oil
Loctite primer or equivalent
Loctite or equivament
Scotch-Grip Rubber Adhesive
RTVSilicone Rubber Sealant
OTCTools Required
T58L-101-APilot Bearing Puller
T58P-6316-D Damper Remover
T59L-100-BPilot Bearing Puller
T61P-6019-B Cover Aligment Tool
T65P-6701-AOil Seal Installer
TTOL-6500-ALifter Puller
TTOP-6049-A Valve Spring Compressor
TTOP-6B070-A Seal Installer
TTOP-6B070-B SeaJ Remover
T71P-6513-B Hydraulic Lifter Compressor
T74P-6666-A Plug Wire Remover
"F77L-9533-B Slide HammerTool
"F79=F-6316-A DamperhstaHer
T82L-6701-AOil Seal Installer
Order from:
OTCDivision of SPXCorporation
655 Eisenhower Dr.
Owatonna, Minnesota 55060
Phone: 1-800-533-0492
or
1-800-533-5338
Eng~,ne/eng
intake Manifold
Removal
[~ 1. Drain cooling system. Removenut (~, then remove flame
arrestor cover.
I[~ 2. Removethe second nut (~), then removehose © and flame

arrestor (~.
I~ 3. Removethermostat housing (~) on intake manifold. Dis-

connect fuel line (~ and fuel pumpvent hose at carburetor. 34741
4. Disconnect spark plug wires at distributor cap and coil.
I~ 5. Removedistributor assembly @. Removecoil and bracket

assembly @.
6. Disconnect wiring harness at coil terminals, engine tempera-

ture sending unit, choke and other connections as necessary.
7. Disconnect throttle cable (~ at carburetor. Remove

throttle
cabJe bracket (~ from manifoJd. Disconnect PCV hose ® at
:carburetor spacer. 34740
8. Removeattaching bolts, and removeintake manifold, decelera-

tion valve, and carburetor as an assembly.
if necessary to pry manifold awayfrom cylinder heads, do

,not damagegasket sealing surfaces.
9. Removeand discard intake manifold gaskets and seals.
Cleaning
Removeall gasket material from the machined surfaces of the

!manifold. Cleantile manifold in a suitable solvent and dry it with 34738
compressedair.
llnspection
Ilnspect the manifold for cracks, damagedgasket surfaces, or

other defects that wouldmakeit unfit for further service. Replace
alJ studs that are stripped or otherwise damaged.Removeall
filings and foreign matter that mayhave entered the manitfold as
a result of repairs.
Ilnstallation
1. Clean mating surfaces of intake manifold, cylinder heads, and

cylinder block. Use a solvent such as Ford Spot Remover(B7A-
19521-A), Cleaning solvent or similar degreasing agent.
E ngine/eng 4-3
[~ 2. Appaya 1/e in. diameter bead of silicone rubber sealer (~)
(C3AZ-19562-A or B) in and along the joint, the full width of the
cylinder block sear mounting surface (~) (four corners) as shown.
EEl 3. install the cylinder head to manifold gaskets ©, and the

front and rear intake manifold to cylinder block seals @. Apply a
1A8 in. bead of sealer (~) at the outer end of each intake manifo0d
seal for the full width of the seal.
[~ This sealer sets up within 15 minutes after application, so
assemblyshould proceed promptly,
4. Carefully lower intake manifold into position. Whenintake

manifold is in place, run finger around seal area to be sure seals
are in place, if seals have shifted, removemanifold and reposition
seals.
%
[~] 5. Be sure intake manifold gaskets are properly aligned, then
install attaching bolts. Tighten snugly to manifold, then tighten
bolts in recommendedsequence to proper torque. Repeat torque
sequence, tightening bolts again to original torque value. Be-
cause the center manifold bolts becomeloose, re-torque mani-
®
fold bolts seasonally.
DE] 6. install thermostat housing and adaptor assembly on DR2215
intake manifold. Install distributor and hold downclamp.
[~E] 7. Connect PCVhose to carburetor spacer.
E~ Z~ 8. Connect fuel line to carburetor. Tighten line nut

securely. Instalm coil and bracket assemblyto intake manifold.
EEl 9. Connect engine harness wiring to coi{, choke and temper-

ature sender.
EEl 10. Attach throttle cable bracket to manifold and throttle

cabZe to carburetor and anchor block.
DE] 31. Connect spark plug wires to distributor cap, and high
tension lead to coil. Be sure plug wires are replaced in proper
order to ensure correct firing order. See Ignition Systemsin the
Electrical~Ignition SystemWorkshopManual.
[~ Z~ 12. install flame arrestor and cover. Makesure engine

compartmentis free of fuel vapors, Start engine and check for
fuel leaks. Check and adjust ignition timing. Check engine for
cooling leaks.
EE] 13. After engine reaches normal operating temperature,

retighten manifold bolts and nuts to proper torque in correct
sequence.
4-4 DR2666
Safety Related Englne/eng
34737 34736 34735
Exhaust Manifold Replacement

Removal
[~ 1. Loosen six hose damps ~ holding exhaust hoses to

exhaust elbow (~).
2. Lubricate lower hose and exhaust pipe with a soapy water

solution, and slide hose downonto pipe.
[=~ 3. Removeexhaust elbow from high-rise hose. 34726
4. Starboard manifold only, removeelectrical cable from J-clamp.
[~ 5. Removethe four screws ® securing high-rise elbow O.

Removethe elbow and discard the gasket.
6. Loosen clamp and pull water hose off front of manifold.
7. Pull spark plug leads off spark plugs. Mark plug wires to ensure
correct firing order.
[~ 8. Unscrew eight Iocknuts and hock washers holding mani-

25927A
fold to mounting studs. Pull manifold off studs.
9. Removeand discard exhaust manifold gasket.
Instal|ation
[~ 1. Install a new exhaust manifold gasket. Gasket ports, must
completely align with exhaust openings.
[~ Gasket can be correctly installed in onny one position. If

improperly installed, gasket will block off part of each exhaust
port and/or block access to spark plugs.
25926
Engine/eng 4- 5 25924A
2. Slide manifold onto studs. Attach lock washers and
tocknuts, and tighten Iocknuts to 20-26 ft. Ibs. (27-35 N-m).
3. Coat a new gasket with Gasket Sealing Compound and place it

on manifold. Install high-rise enbow. Tighten elbow screws to
12-18 ft. ibs. (16-24 N-m).
[~] 4. Attach water hose to nipple at front of manifold and
tighten clamp.
5. Starboard manifold only, secure electrical cable in J-clamp.

2592.3
6. Attach spark plug wires to plugs. Makesure firing order is
correct.
[~] 7. Lubricate upper (large diameter) outside surface of ex-

haust elbow with a soapy water solution, and push elbow into
high-rise hoseuntil it seats.
[~ 8. Lubricate lower end of exhaust elbow and slide Bower

hose up onto elbow. Position hose so that it equally covers elbow
and exhaust pipe.
Z~ [~ 9. Install the six hoseclampsand tighten themsecure|y.

15527
Runengine and check for exhaust leaks.
Circulating PumpReplacement
Removal
1. Drain all water from engine block.

[’~ 2. Loosen the circulating pump pulley bolts, but don’t
removethem at this time. Note, belt tension will keep the pump
from turning while bolts are removed.
15545
3. Release tension on the alternator and power steering pump
belts, then remove them.
4. Unscrewthe pulley bolts, and slide the pulley offthe circulating

pump hub.
[~ 5. Removethe two power steering bracket bolts.

15546 15547 25921
[3 6. Removebrace from alternator bracket to power st,eering

pump.
7. RemoveTorx head bolt ~) and spacer and remove power

steering pump.
[~ 8. Removealternator brace from circulating pumpby remov-

ing bolt and lock washer,
[~ 9. Loosen hose clamp, and pual large hose off circulating

pump.
25920
[~ 10. Take out alternator bracket bolts. Removealternator and

disconnect electrical leads at back of alternator. Set alternator
aside.
~’2-~ 11. Removeall pump mounting boSts. Lightly strike pump
with soft hammerto free it from the mounting gasket. T~ke off
pump, then remove and discard gasket.
installation
11. Thoroughly clean gasket surface on bmock.Coat both sides of a

new gasket with Gasket Sealing Compoundand position it on 15550
block. Carefully align bolt homesand water passages.
2. install circulating pump. Screw in all bolts except those

that attach the alternator and power steering pump bre~ckets.
Tighten bolts to 1:2-18 ft. Ibs. (17-24 N-m)o
15658
25920A 15529
EEl 3. Push aarge water hose onto pumpinlet and tighten clamp
securely.
I-2] 4. Place spacer and Torx head bolt behind rear power
steering pump bracket and secure to block. Attach two power
steering pump bracket screws and lock washers.
EEl 5. Attach the alternator and alternator bracket to the circulat-

ing pumpwith screws, lock washers and flat washers. Tighten the
screws to 18-20 ft. Ibs. (24-27 N.m).
25%21
6. Attach electrical leads to back of alternator.
7. Attach alternator brace to circulating pumpcover. Do not

tighten pivot bolt at this time.
EEl 8. Attach power steering pumpbrace to alternator bracket

with screw and lock washer.
EEl 9. Align the pulley and pumphub screw holes, then slide the
pulley onto the pump. Install the screws and lock washers and
tighten them to 14-20 ft. Ibs. (19-27 N-m).
15528
10. Install the power steering pumpbelt and position it in the
innermost pulley grooves. InstaJJ the aJternator belt in the next
outer groove.
The two belts are different lengths. The power steering

pumpbelt is longer and goes on first.
11. Tension both belts as recommended;see General information

section. Tighten all power steering and alternator bracket bolts
securely.
12. Run engine and check for water leaks.

15527
4-8 Engine/eng
Cylinder Head
Removal
1. Completelydrain cooling systemto ensureno water remainsin
the intake manifold, cylinder heads,exhaustmanifolds, hosesor
block.
:2. Disconnect the spark plug leads at the plugs. Removethe
exhaustmanifolds, then spark plugs.
3. Remove the upperand lower intake manifolds. SeeUpperintake
Manifold Removalin the Fuel SystemService Manual.Seeintake DR4858
Manifoldin this chapter.

4. Removeany components, brackets or clamps that may be
attachedto the front or rear of the cylinder heads.Notetheir posi-
®
t;ion so that they canbe propedyreinstalled.
5. Remove
the rocker armcovers. Discard the old gaskets.
6. Loosenthe rocker armbolts so that the rocker armsmaybe

rotated. Remove the pushrods in sequence
so they can be installed
®
in their original positions. -<
DR5601
[8~ 7. 5.0 Liter Only: Remove and inspect cylinder headbolts.
Retainstandardheadbolts (~; they can be reused. Discard"torque
to yield" headbolts (~); replace themwith new"torque to yield"
headbolts. Lift the headoff the block. Discardheadgasket.
8. 5.8 Uter Onb/: Removethe cylinder headattaching bolts andlift
tihe headoff the block. Discardheadgasket.
Installation
F~’-R3
L ~_~.J1. Cleanthe cylinder head,intake manifold,rockerarm(’overs
DR4859
andcylinder block gasket surfaces. If the headwasremovedfor a
cylinder headgasket replacement,checkflatness of the headand
block gasket surfaces. Surface must not deviate morethan 0.003
in. (0,076 mm)inany 6 in. (152,4 mm)area, and .006 in. (0,152
ram)overall.
2. A specially treated compositiongasket is used. Do not apply
sealer to a compositiongasket.Position the newheadgasket over
the alignment dowels.Place the headon the block and insert the
attachingbolts.
Englne/eng 4-9
[~ 3. Thecylinder headbolts are tightenedin two stepsfor air 5.8
liter engines,andin either twoor three steps(torqueto yield method}
for the 5.0 liter engine dependingon which type headbolts are
used.Followthe illustrated torque pattern, andtighten as follows:
,~WARN|NG:Donot reinstall totrlUe to ~eld headbolts. Torqueto
yield headbolts mustbe replaced oncethey are re-
moved.
¯ 5.0 Liter Engineswith torqueto yield bolts:
Step1. 25-35ft. ab. (33,8 - 47,4 Nm)
Step2. 45-55ft. Ub. (61,0 - 74,5 Nm)
Step3. Turnall bolts in sequence additional
° °
85 -95 (¼ turn}
o 5.0 Uter Engineswith standardhex headbolts:
Step 1. 55-65ft. lb. (74,6 - 88,2 Nm)
Step 2. 65-72ft. lb. (88,2 - 97,6 Nm)
e 5.8 Liter Engines:
Step 1. 95-105ft. lb. (128,8 - 142,4 Nm)
Step 2. 105-112ft. lb. (142,4- 151,9 Nm)
4. Cleanthe pushrods in solvent. Blowout the oil passagein the
pushrods with air. Checkthe endsfor nicks, groves, roughnessor
excessivevvear. Visually checkpushrods for run-out or with a dial
indicator. Replacepushrod if run-out exceeds0.015 in. (0,381
mm)at any point. Do not attempt to straighten and reuse push
rods.
5. Lubricate the rocker armendof pushrod with FordMultipurpose
GreaseDOAZ-19584-AA or equivalent, and instalJ themin their
DR2599
originaJpositions.
6. Lubricate the valve stem ends with Ford Multipurpose Grease
DOAZ-19584-AA or equivalent.
~] 7. Lubricate the rocker arms and fulcrum seats with Ford

Multipurpose GreaseDOAZ-19584-AA or equivament. Install the
rocker armsfollowing the procedureunderValveRockerArminstal-
lation.
8. Clean the rocker armcover gasket surfaces. Securenewgas-
kets in the coverswith gasketsealer to ensureproperhole aJign-
ment.Install the covers; tighten the mountingscrewsto 36-60in.
lb. (4-8 Nm).
9. Install the intake manifold.Seeintake Manifoldin this chapter.
10. Install any components,
brackets, or clampsthat wereremoved.
11. Install spark plugs, and the exhaustmanifolds, then connect
the spark plug ~eads.
4-10 Engineleng
Valve Spring, Retainer and StemSeal
RemovaU
Broken valve springs, or damagedvalve stem seals and retainers,

may be replaced without removing the cylinder head, provided
damageto the valve or valve seat has not occurred.
1. Remove
rockerarmcover.
2. Removethe applicable spark plug and bring the piston to the
top of the bore to prevent accidental loss of the valve into the DR4861
cylinder.
3. Removethe rocker arm fulcrum bolts, fulcrum seats, i’ocker

arms and push rods from the applicable cylinder.
4. fnstall an air line with an adapter in the spark plug hole and
apply air pressure to the cylinder. Failure of the air pressure to
hold the vamvein the closed position is an indication of valve seat
damage,and requires removal of the cylinder head.
E3~ 5. Install the fulcrum bolt and position Valve Spring Com-
pressor Tool TTOP-.6049-Aor equivalent as shown. Compressthe DR4862
valve spring and removethe retainer locks, spring retainer, sleeve
and valve spring.
6. Removeand discard the valve stem seal.

~ If air pressure has forced the piston to the bottom of the
cylinder, any removal of air pressure will allow the valve "to fall
into the cylinder. A rubber band, tape or string wrappedaround
the end of the valve stem will prevent this condition and will still
~llow enoughtravel to check the valve.
7. Inspect the valve stem for damage.Rotate the valve and check
1:he stem tip for eccentric movementduring rotation. Movethe
vane up and down through normal travel in the valve guide and
check the stem for interference, if the valve has been damaged,
it’ll be necessaryto removethe cylinder head,
Installation
1. if the condition of the valve stemprovedsatisfactory, iub,ricate

the valve stem with the recommendedengine oil Hold the valve
in the closed positiion and apply air pressure within the cylinder.
~4-’-] 2. Install a newvalve stemseal on the valve guide. Seal must
be bottomedon guide. Place the spring in position over the valve,
and install the spring retainer and sleeve. Compressthe valve
spring and install the spring retainer locks. Remove the compres-
sor tool and fulcrum bolt.
3. Lubricate the upper push rod ends with Ford Multi-Purpose
Grease DOAZ-19584-AA or equivalent, and install the push rod.
Apply the samegrease to the tip of the valve stem.
4. Apply Ford Multi-Purpose Grease DOAZ-19584-AAor equiva-

lent to the rocker arms and fulcrum, install the rocker arms,
fulcrum and fulcrum bolts. Tighten the bolts to 18-25 ft. lbs. (24-34
N-m).
5. Turn off the air and removethe air line and adapter. Install the
spark plug and connect the plug wire.
DR4863
6. Install the rocker arm cover using new gaskets; follow the
procedure under Rocker Armand Cover Installation.
Front Cover and Timing Chain
Removam
1. Refer to Citcu|ating PumpRemovalsection. Perform all steps

except removal of the pump. Leave it attached to the front cover.
[~] 2. Remove the crankshaft pulley. Unscrew the damper

attaching bolt and washer. Attach DamperRemover T58P-6316-D
or equivalent, and pull vibration damperoff crankshaft.
3. Removethe oil pan-to-cylinder block front cover attaching

bolts. Use a thin-bladed knife to cut the oil pan gasket flush with
the cylinder block face prior to separating the cover from the
block.
4. Removethe cylinder front cover and circulating pumpas an

assembly. Discard the front cover gasket.
5. Checkthe timing chain deflection. If deflection exceeds0.500

in. (12,7 mm), replace the chain and sprockets.
4-12 Englne/eng
[2---] 6. Crank the engine until the timing markson the sprockets
are positioned as shown.
7. Removethe camshaft sprocket cap screw, washers and fuel

pumpeccentric. Slide both sprockets and the timing chain for-
ward, and remove them as an assembly.
installation
1. Position the sprockets and the timing chain on the cam-

shaft. Be sure the timing markson the sprockets are positioned as
shown. DR4864
3r~ 2. Install the fuel pump eccentric, washers and camshaft

sprocket cap screw. Tighten the sprocket cap screw to 40-45 ft.
Ibs. (55-61 N.m).
3. Clean the cylinder front cover, oil pan and the cylinder block
gasket surfaces. Clean the oil pan gasket surface where the oil
pan and front cover fasten.
Install a newoil seal following proceduresunder Front Oil Seal

Removaland installation.
DR4865
4. Lubricate the timing chain and sprockets with heavy engine oil.
5. Coat the gasket surface of the oil pan with sealer. Cut and
position the required newgasket on the oil pan and apply .’sealer
at the corners. Install the pan sealer as required. Coat the gasket
surfaces of the block and cover with Ford Perfect Seal Sealing
CompoundB5A-199554-A (ESR-M18P2-A) or equivalent, and po+
sition a new gasket on the block.
6. Position the cylinder front cover on the cylinder block. Usecare

wheninstalming the cover to avoid seal damageor possible gasket
mislocation.
DR4866
I-E] 7. Install the cylinder front cover-to-seal alignment using
Front Coyer Aligner Tool T61P-6019-Bor equivalent.
8. It maybe necessary to force the cover downwardto sliightly

compress the pan gasket. This operation can be facilitated by
using a suitable tool at the front cover attaching hole locations.
9. Coat the threads of the attaching screws with Ford Perfect Seal
Sealing CompoundB5A-19554-A (ESR-M18P2-A) or equivalent
and install the screws. While pushing in on the alignment tool,
tighten the oil pan-to=coverattaching screwsto 9-11 ft. Ibs. (13-14
N.m). Tighten the cover-to-cylinder block mounting screws to
12-18 ft. Ibs. (17-24 N-m). Removethe alignment tool.
10. Apply Ford Multi-Purpose Grease DOAZ-19584-AA or equiva-

lent to the oil seal rubbing surface of the vibration damperinner
hub to prevent damage to the seal and to the front of the
crankshaft for damperinstallation.
E=~ine/eng 4-13
[~ 11. Line up the crankshaft vibration damper keywaywith the
key on the crankshaft, tnstali the vibration damperon the crank-
shaft using Damper Remover/Replacer Tool T79T-6316-A or
equivalent. Install the cap screw and washer. Tighten the screw to
70-90 ft. Ibs. (95-122 N-m). install the crankshaft pulley,
12. Completethe remainingsteps under Circulating Pumpinstal-

lation.
13. Operate the engine at a fast idle to bring the engine up to

operation temperature. Checkand adjust ignition timing to speci-
fications in Section 6, ElectricaUignition Workshop Manualunder DRY67
Distributor, Finish Timing.
Front Oil Seal

Remova|
1. Removethe crankshaft pulley from the vibration damper.

Removethe damper attaching screw and washer, install the
puller on the crankshaft vibration damperand removethe vibra-
tion damper.
2. Place the Front Cover Seal Remover TTOP-6B070-Bor DRd868

equivalent onto the front cover plate over the front seal as shown.
Tighten the two through-bolts to force the seal puller under the
seal flange.
3. Alternately tighten the four puller bolts one-half turn at a time

as shownto pull the oil seal from the front cover.
installation
EEl 1. coat a new front cover pUate oil seal with Ford Multi-
Purpose Grease DOAZ-19584-AA or equivalent. Place the front oil
seal onto Front Cover Seal Replacer "F70P-6B070-Aor equivalent.
DR4869
Place the sleeve and seal onto the end of the crankshaft and push
it toward the engine until the seal starts into the front cover.
DE] 2. Place the installation screw, washer and nut onto the end
of the crankshaft. Thread the nut against the washerand installer
sleeve to force the seal into the front cover plate. Removethe
installation tool from the crankshaft.

hub to prevent damageto the seal. Apply a white lead and oil
mixture to the front of the crankshaft for damperinstallation,
4, Line up the crankshaft vibration damperkeywaywith the key on

the crankshaft. Install the vibration damperon the crankshaft.
install the cap screw and washer. Tighten the screw to 70-90 ft.
Ibs, (95-122 N-m). install the crank pulley. Makesure the pulley
bottomed on the damper pilot.
4-14 Englne/eng
Oil Pan
Removal
1. Removeengine from boat following procedures in Engine
Removaland Installation section found elsewherein this work-
shop manual.
2. Drain the crankcase.Unscrewthe dipstick tube.
~. Removethe oil pan attaching bolts and removethe pan braces

and pan.
4. Refer to cleaning and inspection procedures.Checkthe gasket

surface for damage causedby overtightenedbolts. Straighten the
surface as requiredto restore original flatness.
Cleaning
Scrapeany dirt or metal particles from inside of pan. Scrape all

old gasketmaterial from the gasketsurface. Washpanin a solvent
and dry it thoroughly.
inspection
Checkthe panfor (:racks, holes, damaged

drain plug threads, or
damaged gasket surface.
Inspect for damage

(unevensurface) at the bolt holes caused
overtorquing mountingbolts. Straighten surfaces as req~jired.
Repair any damage,or replace the pan if repairs cannot be made
satisfactorily.
installation
E4---i 1. Cleanthe gasket surfacesof block andoil pan. Coatthe
block surface andoil pangasketsurfacewith oil-resistant sealer.
Position oil pangasketon cylinder block.
E E] 2. Holdthe oil panin place againstblock andplacepan]brace
against pan. Install a bolt finger tight on eachside of oil panto
hold it in place, then install the remainingbolts. Tightenthe bolts
from the center outwardin eachdirection. Tighten ¼-20bolts to
9-11ft. Ibs. (13-14N-m).Tighten¥18-18bolts to 9-11ft. Ibs. (13-14
N-m).
~5-~ 3. Install dipstick tube fitting to pan; leave screwloose.
Orient fitting andattach dipstick tube. Thentighten both fitting
screwandflare nut to 15-18ft. Ibs. (20-24N-m). DR2673
4. Fill engine to proper level with recommended

engine oil.
5. install engineinto boat following proceduresin EngineRemov-

al andInstallation section. Start engineandcheckfor leaks;.
31576
Oil Pump
Removal
1. Removeengine from boat by following procedures in Engine

Removaland installation section.
2. Removethe oil pan and related parts following the procedure

under Oil Par= Removal.
[~] 3. Removeoil pump inlet tube and screen assembly.

DR4591
DE] 4. Unscrew oil pump mounting screws. Remove pump and
intermediate driveshaft.
Disassembly
1. Removethe four screws and washers securing the oil pump

cover to the oil pump, then oil pumpcover.
2. Removeoil pumpouter rotor and rotor shaft assembly from the

oil pump housing.
3. Removethe cotter pin that secures the relief valve plug in the DR4590
oil pump housing. To remove the plug, drill a small hole and
insert a self-tapping screwin the relief valve pUug. Use pliers to
removeplug from oil pumphousing. Use care to prevent the loss
of the relief valve spring.
4. Removespring and relief valve from oil pumphousing.
Cleaning
Washall parts in solvent and dry them thoroughly with com-

pressed air. Use a brush to clean the inside of the pumphousing
and the pressure relief valve chamber. Ensure all dirt and metal
particles are removed.
inspection
1. Refer to Specifications for clearances and service limits.
2. Check the inside of the pumphousing and the outer race and
rotor for damageor excessive wear.
3. Check the mating surface of the pumpcover for wear. If the

cover mating surface is worn, scored or grooved, replace the
cover,
32364
~] 4. Rest rotor assembly on flat surface. Measuretip clearance
with a feeler gauge. Tip clearance must not exceed 0.004 in. (0,10
mm).
[~ 5. With the rotor assembly installed in the housing, measure

the outer race to housing clearance (~). Your feeler gauge reading
must be 0.001-0.013 in. (0,03-0,33 ram).
DR1840
4-16 CobrEng/eng
E5-~[ 6. Place a straight edge ~ over the rotor assemblyarid the
housing. Measurethe cmearance(rotor end play) ©, between the
straight edge and the rotor and outer race. Your reading must be
0.001-0.005in. (0,03-0,13 ram).
7. Checkthe driveshaft to housing bearing clearance by measur-

ing the O.D. of the shaft and I.D. of the housing bearing. Correct
c~earanceis 0.0015=0.0029in. (0,04-0,07 mm).
8. ff the pumpfails either Step 4, 5, or 7, replace the oil pump

assembly. The outer race, shaft and rotor are repnaceabie only as
an assembly.
9 Inspect the relief valve spring for a collapsed or worncondition.

Checkthe relief valve spring tension.
¯ 5.0 FL Models: 1.74in. {44,2 mmllength with a 10.6-12.2 ©

lb. (4,80-5,53 kg) load. DR1841
e 5.8 FL Models: 2.49 in. (63,2 mm)length with a 18.2.-20.2

rb. (8,25-9,16 kg) load.
ff the spring tension is not within specifications, and/or spring is

worn or damaged, replace the spring. Check the relief valve
piston for scores and free operation in bore.
~ot-~ The internal componentsof the oil pumpare not serviced.
If any component is out of specifications, the pumpassembly
must be replaced.
Assembly
1. Instal[ relief vamve, spring and renief valve pUugin oil pump
housing. Press plug inward until it seats, then install the cotter
pin.
2. Install outer rotor and rotor shaft in housing. Be sure that

identification markon outer rotor is on the sameside as identifica-
tion mark on inner rotor. Fill the housing with engine oil for
priming purposes.
3. Install the cover plate and tighten the four screwsto 72-1z.0
r~ in.
Ibs. (8-18 Nora).
[n,sta|lation
1. Primeoil pumpby filling pumpinlet port with engine oil. Rotate

pumpshaft to distribute oil within pumpbody.
2. Position intermediate driveshaft into distributor socket. With

seat firmly seated in distributor socket, the stop on the shaft
should touch roof of crankcase. Removeshaft and position stop
as necessary.
Englne/eng 4-17
[~ ~ 3. With stop properly positioned, insert intermediate
driveshaft ~) into oil pump.install pumpand shaft as an assem-
bly. Donot attemptto forcepump into positionif it will not seat
readily. The drive hex maybe misaligned with the distributor
shaft. Rotate intermediate driveshaft to align. Tighten oil pump
mountingscrews(~ to 22-32ft. lbs. (30-43N-m).
EEl 4. Cleanand install oil pumpinlet tube and screenassembly
using a newgasket. Tighten mountingscrews© to 10-15ft. Ibs.
(14-20N.m). Attach oil pumptube to engineblock andtighten nut
(~) to 22-32ft. Ibs. (30-43N.m). 1 DR4590
5. InstalJ oiU pan and related parts as outlined under Oil Pan
Installation.
Crankshaft Rear Oil Seal

All models have a one piece crankshaft rear oil seal. This
completeseal is replaced without removingcrankshaft.
Removal

Removaland instal|ation section. DR4591
2. Remove
starter motor.
3. Remove
flywheel housing, coupling, flywheel and cover. #
FRONTOF ENGINE
4. Usinga sharp awl, punchone hole into the seal metal surface
betweenthe lip and engine block.
5. Screwin the threaded end of Slide Hammer Tool T77L-9533-B

or equivalent. Use the slide hammerto removethe seal. Use
caution to avoid scratching or damagingthe oil seal surface.
Rnstallation
1. Lubricate newseal with engineoil.
r~ 2.5.0 FLModels:Position oil seal with seal lip facing forward
on rear Oil Seal Installer T82L-6701-A
or equivalent. Position seal
and tool on rear of the engine. Alternate bolt tightening to
properly seat seal. Therear face of seal mustbe within 0.005in.
(0,127 ram)of rear face of block.
~] 5.8 FL Models: Start seal with seal lip facing forward and
install it with the rear Oil Seal Replacertool T65P-6701-A or
equivalent. Keeptool straight with centerline of crankshaft and DR1860
install seal until tool contactscylinder block surface.
FRONTOF ENGINE
DR2513
4-18 Engine/eng
E~ Removethe tool and inspect the seal to ensure it was not
damagedduring installation.
3. Install flywheel cover, flywheel, coupling and housing.
4. install starter motor.
5. mnstall engine into boat following procedures in Engine Remov-

al and Instal|ation section.
Valve Rocker Arm and Cover

Removal
1. Disconnect spark plug wires from spark plugs by gra=~ping,

twisting and pulling molded cap only, using Spark Plug Wire
Remover"I-74P-6666-A or equivalent.
21. Removethe e×haust manifold.
3. Removethe valve rocker arm cover(s).
L~ 4. Removevalve rocker arm bolt (E), fulcrum ~), rocker arm

and fulcrum guide (~.
Inspection - Rocker Arm
~1: the pad at valve end of rocker armhas a groovedradius, replace

rocker arm. Do not attempt to true this surface by grinding.
inspection - PushRod
Checkends of push rods for nicks, grooves, roughness or exces-

sive wear.
The push rods can be visually checkedfor straightness while they

are installed in the engine by rotating them with the valve closed.
They also can be checked with a dial indicator for a maximum
runout of 0.015 in. (0,38 ram). if the push rod is visibly bent,
should be replaced.
Installation
1. Apply Ford Multi-Purpose Grease DOAZ-19584=AA or equiva-

lent to the top of the valve stems, the rocker arm and fulcrum
seats, and upper end of push rods.
Engine/eng 4=19
i
Notej Thefollowingprocedure will placethe lifter on a flat of the
camshaft,not on a portionof the lobe to allow easyinstallation of the
rocker arms.
E~] 2. Position No. 1 piston on TDCat the end of compression

stroke, Position @, and install rocker arm, fulcrum, fulcrum guide and
bolt on the following valves:
¯ No. 1 Intake, No. 1 Exhaust

® No. 4 Intake, No. 3 Exhaust
o No. 8 Intake, No. 7 Exhaust DR1845
E~ 3. Rotate crankshaft to Position ®, 180° from TDC@, and install ~) TDC

rocker arm, fulcrum, fulcrum guide and bolt on the following valves: 180° from (~)
@ 270° from (~)
E~ 4. Rotate crankshaft to Position ©, 270° from Position @, and

install rocker arm, fulcrum, and bolt on the following valves:
o No. 2 Intake, No. 4 Exhaust

o No. 6 Intake, No. 8 Exhaust
5. Besure that the fulcrumbaseis insertedin its slot on the cynin-

tier headbefore tightening the fulcrumbolts. Tighten fulcrum bolt
to 18-25 ft. Ibs. (24-34 N.m). Checkvalve clearance following proce-
dures under Valve Clearance Checking Procedure.
6. Cleanandinspect gasket surfaces of engineblock andvalve cover(s).

Inspect valve cover gasket sealing surface(s) for damageand distor-
tion due to overtighting of bolts. Place a newgasket in cover(s), mak-
ing sure that tabs of gasket engagenotches provided in cover(s).
7. Position cover(s) on cylinder head gasket surface(s). Make

gasket seats evenly all aroundhead. Install bolts. Thecover is tight-
enedin two steps. Tighten bolts to 36-60 in. Ibs. (4--6 N-m). Wait two
minutes, then tighten bolts to the samespecifications. If the starboard
cover was removed,install PCVvalve.
8. Install exhaust manifold. Connectspark plug wires. Start engine

and checkfor leaks.
4-20 Engine/eng
VamveClearance Check
Thevalve arrangementis on the port bankis E-I-E-I-E-I-E-I andon the

starboardbankis I-E-I-Eq-E-I-E.
Valvestemto valve rocker armclearanceshouldbe within specifica-

tions with the hydraulic lifter completelycollapsed.Repeated’valve
reconditioningoperations(valve and/orvalve seat refacing) or valve
seat recessionwearcausedby (extendeduse) will decreasethe clear-
anceto the point that, if not compensated
for, the hydrauficvalvelifter
wilt ceaseto function andthe valvewill be heldopen.
iNote
’ Theuseof positive stop rockerarmbolts eliminatesthe need
to adjust the valveclearance.However, to obtain the specifiecl valve DR1846
clearance,it is importantthat all vanvecomponents be in a serviceable
conditionandinstalled andtightenedproperly.
To determinewhethernewservice parts are necessary,makethe fol-

lowing check:
~.~ 1. Remove the PURPLE wire from the "1" terminal of the starter
assist solenoidso the enginedoesnot start, install an auxiliary
starter switch. Crankthe enginewith the ignition switchOFFun=
till the No. 1 piston is on TDCafter the compression stroke.
E2-’] 2. Withthe crankshaftin the positions designatedin Steps2, 3

and4, position the Hydraulic Lifter Compressor Tool T71P-6513-B @
or equivalenton the rocker arm.Slowtyapply pressureto bleed down
the hydrauliclifter until the plungeris completelybottomed.Holdthe
lifter in this position andcheckthe available clearancebetween the
rocker armandthe valve stemtip with a feeler gauge®.
3. With the No. 1 piston on TDCat the endof the compression DR1845
stroke as shownin Position @,checkthe following valves:
TDC
~) 18;0° from
e No. 1 Intake, No. 1 Exhaust @ 270° from ~)
® No. 4. Intake, No. 3 Exhaust
E’3~ 4. After checkingthe spacingon thesevalves, rotate the crank-
shaft to Position®, 180° fromTDC@,then checkthe following valves:

® No. 7’ Intake, No. 6 Exhaust
E,~;~Jn~o,~
~ SafetyRelated 4-21
E~5. After checkingspacingon these valves, rotate the crankshaft
to Position @,270° from Position @;andcheckthe following valves:
e No. 2 Intake, No. 4 Exhaust

ClearanceSpecifications:
5.0 FL Models
DR1845
Allowable: 0.071-0.193in. (1,8-4,9 mm)
Desirable: 0.096--0.165in. 2,4-4,2 mm) ~) TDC
® 180° from~)
5.8 FL Models @ 270° from(~)
Allowable: 0.098-0.198in (2,5-5,0 mm)

Desirable:0.123--0.173in. (3,1-4,4 mm)
Valve Lifter
Thefollowing procedureis applicable for removingoneor all of the

valvelifters. Beforereplacinga hydraulicvalvelifter for noisyopera-
tion, be sure the noise is not causedby impropervatve clearanceor
by wornrocker armsand/or pushrods.
Dirt, gumor varnishdepositsandair bubblesin the lubricating oil can

causehydraulicvalvelifter failure or malfunction.
Dirt, gumandvarnish can keepa checkvalve from seating andcause

a loss of hydraulicpressure.Anopenvalvedisc will causethe plunger
to forceoil backinto valvelifter reservoirduringtimepushrod is being
lifted to forcevalvefromits seat.
Air bubblesin the lubricating systemcanbe causedby too high or too

low an oil level. Air mayalso be drawninto the lubricating system
throughan openingin a damaged oil pick-uptube. Air in an oil lifter
cancausea loss of pressureto lifter.
RemovaU
1. Remove
intake manifoldandrelated parts following procedures
under
Intake Manifold.
2. Removethe valve rocker armcovers. Loosenthe rocker armbolts

andturn rocker armsto oneside.
3. Remove the pushrods in sequence

so they canbe installed in their
original positions.
4. UsingHydraulic TappetPurler T70L-6500-A or equivalent, remove

lifters andplacethemin a rackso that they canby installed in their
original bores.
Cleaning
Thoroughly clean all the parts in cleaning solvent and wipe them
with a clean, lint-free cloth.
inspection
inspect the parts and discard the entire lifter assemblyif any part
shows pitting, scoring, galling or evidence of non-rotation. Re-
place entire assemblyif plunger is not free in the body.
Checkfor freeness of operation by pressing downon the push rod

,cup. Thelifters can also be checkedwith a hydraulic tester to test
leak-downrate. Follow tester manufacturer’s instructions ’to per-
form test.
ilnstallation
1. Clean outside of valve lifters. Lifters and bores are to be

lubricated with specified engine oil before instaJlation, install
lifters in their original bores. Checkany newlifter for free fit in
bore to which it has been installed.
:2. Apply Ford Multi-Purpose Grease DOAZ-19584-AAor equiva-

lent to valve stem tips and push rod ends. install push rods in
original positions,,
3. Lubricate rocker arms and fulcrum seats with Ford Multi-

Purpose Grease DOAZ-19584-AA.
4. Position the rocker arms over the push rods and tighten the
bolts following the procedure under Valve Rocker Arm installa-
tion. Adjust valve clearance following procedure under Valve
Clearance Check,
!5. install rocker arm covers following procedure under Rocker

Arm and Cover installation.
6. Install intake manifold and related parts following the pro-

cedures under intake Manifold.
Core Plugs
Removal
To removea large core plug, drill a I/2 in. (12,7 ram) hole in center
of plug and remove with an Clutch Pilot Bearing Puller Tool
T59L-100-Band T58L-101-Aor pry it out with a large drift punch.
Ona small core plug, drill a 1~ in. (6,37 ram) hole in center of plug
and pry it out with a small pin punch. Clean and inspect plug bore.
Prior to installing a core plug, plug bore should be inspected for

any damagethat ’would interfere with proper sealing of plug. if
bore is damaged ill will be necessaryto true surface by boring for
the next specified oversize plug. Oversize (OS) plugs are identi-
fied by OSstampedin fiat located on the cup side of plug.
Lightly coat plug and/or bore with an oil resistant (oil galley)
water-resistant (cooling jacket} sealer, and install it following
procedure for cup-type or expansion-type below:
Installation - Cup-Type
[~ Cup-type core plugs (~) are installed with flanged edge

outward. The maximumdiameter of this plug is located at outer
edge of flange. The flange on cup-type plugs flare outward with
largest diameter at outer (sealing) edge (E).
It is imperative to push plug into machinedbore by using a DR1847

properly designed tool. Under no circumstances is plug to be
driven into bore using a tool that contacts flange. This method
will damagethe sealing edge and will result in leakage and/or
plug blow out.
The flanged (trailing) edge must be below chamfered edge

bore to effectively seamplugged bore.
If core plug replacing tool has a depth seating surface, do not seat
tool against a non-machined(casting) surface.
Installation - Expansion-Type
DR1848
Expansion-type core plugs ~ are instalJed with flanged edge

inward. The maximumdiameter of this plug is located at base of
flange with flange (~ flaring inward.
it is imperative to pushor drive plug into machinedbore using a

properly designed tool, Under no circumstances is plug to be
driven using a tool that contacts crowned portion of plug. This
method will expand plug prior to installation and may damage
plug and/or plug bore.
Wheninstalling plug, the trailing (maximumdiameter) must

below chamfered edge of bore to effectively seal bore.
if core replacing tool has a depth seating surface, do not seat tool
against a non-machined(casting) surface.
CamshaftLobe Lift
Checklift of each lobe in consecutive order, and makea note of

the readings.
1. Removevalve rocker arm Cover.
2. Remove valve rocker arm. Install a solid, tappet-type push rod

in push rod bore of camshaft lobe to be checked, or use the
adapter for ball end push rods.
[3-~] 3. Makesure push rod ® is seated against camshaft lobe.
Install a dial indicator so that actuating point ® of indicator is in
push rod socket (or the indicator baln socket adapter is on end of
the push rod) and in same plane as push rod movement.
4. Removespark plugs.
!5. Connectan auxiliary starter switch in starting circuit, Crank

engine with ignition switch OFF.Bumpcrankshaft over until lifter
is on basecircle of camshaftlobe. At this point, pushrod willl be in
its lowest position.
6, Zero dial indicator. Continue to rotate crankshaft slowly until DR1849
push rod is in fully raised position.
7. Comparetotal lift recorded on dial indicator with specifica-
tions:
5.0 FL Models:
Intake: 0.260 in. (6,6 ram)
Exhaust: 0.278 in. (7,1 ram)
5.8 FL Models:
intake: 0.278 in. (7,1 ram)
I’xhaust: 0.283 in. (7,2 mm)
MaximumAllowable Loss: 0.005 in. (0,13 ram)
8. To check accuracy of original indicator reading, continue to
rotate crankshaft until indicator reads ZERO.if lift on any lobe is
below specified wear limits, camshaft and valve lifters operating
on the worn lobe(s) must be replaced as well as any lifter showing
pitting or having a contact face worn flat or concave.
9. Removedial indicator and auxiliary starter switch. Install rocker
arm. NOTE:Do not rotate crankshaft until hydraulic lifters have
had a chance to bleed down. To do otherwise may cause serious
valve damage.Manually bleeding downlifters will reduce waiting
time.
10. Install the valve rocker arm cover.
11. install spark plugs.
CompressionTest:
~ 1. Be sure crankcase oil is at proper level and of correct

viscosity. Makesure that battery is properly charged. Operate
engine for a minimumof 30 minutes at 1200 RPM,or until engine
is at normal operating temperature. Turn ignition switch off;
disconnect B+ lead at ignition coil positive (+) terminal:, then
removeall spark plugs.
:2. Set throttle plates at wide-openthrottle position.
:3. Install a compressiongaugein No. 1 cylinder.
Engineleng ~ Safety Related 4-25

4. Install an auxiliary starter switch in starting circuit. Using
auxiliary starter switch, crank engine (with ignition switch OFF)
at least five compression strokes and record highest reading.
Note approximate number of compression strokes required to
obtain highest reading.
5. Repeat test on each cylinder. Crank engine same number of
compression strokes as was required to obtain highest reading on
No. 1 cylinder.
The indicated compression pressures are considered normal if

mowestreading cylinder is within 75%of the highest. Refer to the
following exampne:
Highest Reading: 140 PSI (6703 kPa)

75%: 105 PSi (5027 kPa)
Jn this example, any cylinder reading less than 105 PSi (5027 kPa)
indicates an improperly seated valve, or worn or broken piston
rings.
If one or more cylinders read tow, squirt approximately one

tablespoon of engine oil on top of the pistons in low reading
cyJinders. Repeat compressionpressure check on these cylinders.
1. If compressionimproves considerably, piston rings are at fault.
2. If compressiondoes not improve, valves are sticking or seating

poorly or valve guides are leaking.
3. if two adjacent cylinders indicate low compression pressures

and squirting oil on pistons does not increase compression, the
cause may be a cylinder head gasket leak between cylinders.
Engine oil and/or coolant in the cylinders couJd result from this
problem.
Positive Closed-TypeVentilation System

A maffunctioning closed crankcase ventilation system may be
indicated by hoping or rough engine idle. Do not attempt to
compensatefor this idle condition by disconnecting the crank-
case ventilation system and making carburetor adjustments. The
removalof the crankcaseventilation system from the engine will
adversely affect fuel economy and engine ventilation with resul-
tant shortening of engine life. To determine whether loping or
rough idle condition is caused by a malfunctioning crankcase
ventilation system, perform the following tests.

1. Remove PCVvalve from its mounting, but leave vacuuminlet
side connectedto hose. If the valve is functioning properly and
riot plugged,a hissing noise will be heardas air passesthrough
valve. A strong vacuumwill be felt whena finger is placed over
valve inlet. Checkfor vacuumleaks in hose line and at all
connections.
2. Reinstall PCVvalve, then removecrankcaseair inlet hose at

flame arrestor connection. Loosely hold a small piece of stiff
paper (such as a 3 x 5 memo card or parts tag card) over opening
at end of inlet hose. After a minute or so, (to allow crankcase
pressure to lower) the piece of paper should be suckedagainst
hoseopeningwith a noticeable force.
I1l£II I11 ill I I ill’l (i]i~ lilt!¯
RemovePCVvalve from its mounting and shake it. A metaNic

c.licking noise should be heard, indicating that valve parts are
free, andnot sticking.
If ventilation systempassesthese two tests, it can be considered

functionally OK,andno further serviceis required.If it fails either
test, replace PCVvalve andrepeat EngineIdling Test.
If systemstill doesnot passtest, clean ventilation systemhoses

and all passagesto induction systemin accordancewith ,estab-
lished procedures.
Servicing PCVValve
Donot attempt to clean crankcase ventilation regulatorv~dve,it

should be replaced. Clean crankcaseventilation systemconnec-
tion(s) on intake manifoldby probingwith a flexible wire or bottle
tirush. Clean hoses, tubes and associated hardwarewith a low-
volatility, petroleum-basesolvent and dry with compressed air. 31588
Front Engine Mounts

1
Removal
[~ ~ 1. Prior to removing a front mount, measuredistance
betweenlarge washer(~) and fiat ® on upper mount bracket.
Recordthis dimensionso mountcan be correctly reassembled.
[2~ 2. Removethe top nut and washersfrom the mount.
[3 3. Removethe two lag screws © and washers securing the 31582
mount.
31580
E~ine/e~ 4-27
~4. Lift enginewith 1500lb. (680 kg) minimum
capacity hoist
to allow remova|of front mounL
[~ 5. Removetwo mountbracket-to-block screws and lock wash-

ers @and removebracket.
Disassembly
[~ Hold mount bolt with a socket, and remove the two

nuts and disassemMe mount. 31578
Assembly
E~ Place small washer® on the mountbott and insert bolt up

through mount. Install large washer® and secure with nut @.
Torqueto 60--75ft. Ibs. (81-102N.m).
Installation
[~ Fully seat front enginemountadjusting bolts into the front en-

gine mount ®. DR4558
~CAUTION Bolt hole @is usedfor 5=8liter blocks only, bolt hole
O is for the 5.0 liter blocks only. Theenginewill be damaged
if
these positions are usedincorrectly.
; Notel The headof support screw and mating contact point on
block mustbe free of paint.
E~] 2. Sprayboth mountbracket-to-blockscrewswith Loctite primer

or equivalent and allow to air dry. ApplyLoctite or equivalent to
both screws. Attach bracket to engine with two screws and wash- 11983
ers. Tightenscrewsto 32-40ft. Ibs. (43-54N.m).
E~ 3. Place a 0.005 in. (0.13 mm)feefer gaugebetweenthe en-

gine block and the engine mountadjusting bolt. Adjust the engine
mountadjustingbolt in or out until a resistanceis felt on the feeler
gauge.
4. Markthe engine mountadjusting bolt head. Back the engine

mountadjustingbolt out exactly onehalf (1/2) turn.
[~ 4. Install upper inner nut and washer® on mountassembly DR4529A
andplace bolt into bracket, then install top nut andwashers@.
5. Set height adjustment, refer to HeightAdjustment.
31577
Height Adjustment
1. Lift enginewith a hoist capableof lifting at least 1500lb.

(580 kg). Position engine at desired height.
[6~ 2. To change engine height, tighten or loosen nuts ~ and @
as required.
[6~ 3. After setting mount position, turn nut @up against
underside of engine bracket and hold nut with a wrench. Tiighten
top nut ~) to 50-70 ft. Ibs. (68-95 N-m).
31581
Any large adjustments to engine height should be fol-
lowed by a check of engine alignment. Failure to check alignment
could result in rapid engine coupler failure.
Removal
EEl 1. Loosen two clamps securing upper hose. Lubricate inside
of hose with a soapy water solution.
EEl 2. Removefour screws, flat washers and lock washers 34723

mounting high=rise elbow. Use a soft hammerto free the elbow
from the manifold. Use a twisting motion to pull high-rise from
hose= Removeand discard the manifold gasket.
Installation
[~ 1. Thoroughly clean manifold gasket surface @. AppBy

Gasket Sealing Compoundto both sides of a new gasket and
place it on the exhaust manifold.
[~ 2. Lubricate the inside of the exhaust hose with a soapy

water solution. Insert the high-rise into the hose with a twisting
34722
motion, and push it into hoseas far as it will go.
3. Position high-rise on manifold, install four screws, flat washers

and lock washers. Tighten screws to 12-18 ft. ibs. (16-24 hi-m).
4. Slide clampsup onto hose and position them in the two surface
channels. Tighten clamps securely.
34721
2601O 34725

Replacement
Removal
[~ 1. Loosen four clamps ~ attaching lower hose, and slide

c~ampsoff the hose.
[~ 2. Lubricate inside of hose, top and bottom, with a soapy

water solution, and slide hose downonto exhaust pipe.
34724
[~ 3. Loosen all clamps on upper hose. Removeintermediate

pipe (~) with a twisting motion.
~] 4. Slide upper hose off high-rise elbow.
DE] 5. Slide lower hose off exhaust Y-pipe.
|nsta|lation
[~ ~ Both the upper and lower hoses have a step in the

inside diameter that must face the intermediate pipe.
26025
[~ 1. Lubricate inside diameter of lower hose with a soapy
water solution. Slide it all the way onto the exhaust Y-pipe.
[~ 2. Place four clamps on upper hose. Push hose all the way
onto high-rise elbow. Position c~ampsin channels at top of hose,
and tighten clamps securely.
~] 3. Lubricate inside of upper hose. With a twisting motion,

insert intermediate pipe ® all the way into the upper hose and
position it as shown. Do not attach the hose clamps at this time.
32366
2602,$
4-30 CobrEng/eng
Exhaust (Flapper) Valve ReplacementSX
Models
L~ 4. Slide lower hose up until it equally overlaps the intermedi-
ate and exhaust pipes.
ET~ 5. Slide two clamps (~) onto upper hose. Slide four remaining
clamps (~ onto lower hose. Position clamps in channels and
tighten securely.
Removal
6373
1. The exhaust valves are at the upper ends of the exhaust pipes.
Removeadaptor pipes and lower exhaust hoses.
~.~ 2. Using a small drift or punch(~), push the exhaust valve pin
~) out of each exhaust pipe.
[~ [~ 3. Remove pin and valve. Push out two rubber bush-

ings.
installation
1. Apply ,Scotch Grip Rubber Adhesive to two new rubber ~75A

bushings and push into each exhaust pipe.
[~ 2. Lightly lubricate exhaust valve pin with oil. Position
valve in each exhaust pipe with long side of valve down. Push pin
through bushing and exhaust valve until flush with both sides of
pipe. Check exhaust valve for freedom of movement.
if the valve is not positioned properly (long lip down),

will restrict exhaust flow and fail to prevent water from backing up
into exhaust system. Boat performance could be adverse, ly af-
fected, and major engine damagecould occur.
6376
3. Install exhaust hoses and adaptor pipes.
6377
Engineleng 4-31 ~78

Engine Coupler Replacement - SX Models
Removal
[~ if coupler is being replaced due to coupler failure (rubber

coupler.

Removaland Installation in this manual.
[~ 2. Cut tie strap ~) holding flywheel housing drain hose to
starter motor, then remove starter. Removesmall screws along
forward edge of bellhousing plate.
3. Unscrew outer nut on ground stud, and take off lock

washer and electrical leads. Removeinner nut, lock washer and
washer. Removesimilar ground stud hardware on opposite side
of block.
4. Removepower steering cooler. Unscrew remaining flywheel

housing bolts, lock washersand washers. Note position of clamps
so they can be installed in original position.
6675
5. Loosen bellhousing with a soft hammer, and pull off
engine.
[~ 6. Unscrewsix nuts and lock washers, then pull coupler off

flywheel.
Installation
DE] 1. Slide coupler onto crankshaft studs, install lock washers

and nuts. Use a crowfoot wrenchand tighten nuts to 40-45 ft. Ibs.
(54-61 N-m).
6710
6712
4-32 67~4
CobrEng/eng
2. Install flywheel housing. Place clamps in their orriginal
positions and attach power steering cooler. Tighten screws to
28-36 ft. ~bs. (38-49 N-m}.
~ 3. Place washer, lock washer and nut on ground stud. Tighten

inner nut to a torque of 20-25ft. Ibs. (27-34 N.m). Attach electrical
leads to ground stud. install lock washer and tighten outer nut
secure|¥. Install ground stud hardwareon opposite side of block.
[1~] 4. Install small screws along forward edge of bellhousing
plate and tighten to 60-84 in. Ibs. (6,7-9,5 N-m). Install starter
motor and tighten screws to 24-30 ft. Ibs. (33-41 N.m). Attach 6711A
flywheel housing drain hose to starter motor with a tie strap.
!5. Install engine irm boat following instructions in EngineRemoval

and Installation section in this manual.
Engine/en9 ~ Safety Related 4-33

TorqueSpecifications - All Models
SCREW FT. LBS iN. LBS. N-m

SiZE
No. 6 7- 10 0,8-1
No. 10 2-3 25-35 3-4
No. 12 3-4 35-45 4-5
V4 5- 7 60 - 80 7- 9
s/16 10- 12 120- 140 14- 16
3h 18 - 20 220 - 240 24 - 27
Use a reliable torque wrench to tighten the parts listed to prevent straining or distorting the parts or
friction which prevents accurate measurementof tightness, it is important that these torque specifica-
C FT. LBS. J [iN, LBSj
Adaptor- Oil Pressure Sender 10-14 14-19

Alternator- Bracket to Pump 18-20 24-27
Camshaft Sprocket 40-45 55-61
Circulating Pump 12-18 17-24
Cover, FlywheeU Housing 60-84 6,7-9,5
Cover Plate, Oil Pump 72-120 8-16
Cylinder Block Cover 12-18 17-24
Distributor Clamp 17-25 23-34
Exhaust Elbow 12-18 16-24
Exhaust Manifold 20-28 27-35
Fitting, Oin Withdrawl Tube 15-18 20-24
Flywheel Cover 60-84 6,7-9,5
Front Mount to 8lock 32-40 43-54
Fuel Pump 18-20 24-27
intake ManifoEd 23-25 31-34
Oil lnnet Tube-to-Pump 10-15 14-20
Oil inlet "PabeBracket 22-32 30-43
Oil Pan(1/4 x 20) 9-11 13-14
Oil Pan (5/16 x 18) 9-11 13-14
Pulmey, Crankshaft 22-32 30-43
Pulley, Circulating Pump 14-20 19-27
Rocker Arm 18=25 24-34
Rocker Arm Cover 36-60 4-6
Starter Motor 24-30 = 33-41
Starter Motor Bracket 18-19 = 22-28
4-34 Engine/eng
TorqueSpecifications- (Cont.)
( FT. LBS.J ~lN. LBS.1
Raw-water Pump Bracket 12-18 17-24

Water Outlet Housing 10-15 14-20
Carburetor 10-14 14-19

Connecting Rod
5.0 FL 19-24 26-33
5.8 FL 40-45 54-61
Couple~r, Engine 40-45 54-61
Flame Arrestor 30-40 3,4-4,5
Front Mount (top) 50-70 68-95
Vibration Damper 70-90 95-122
Withdrawl Tube to Fitting 15-18 20-24
m
Cylinder Head(5.0 FL)
Step 1 25-35 33,8-47,4
Step 2 45-55 61,0-74,5
Step 3 Tighten an additional 85°- 95° (1/4 turn)
Cylinder Head(5.8 FL)
Step 1 95-105 129-143
Step 2 105-112 143-151
Main Bearing Cap
5.0 FL 60-70 - 81-95
5.8 FL 95-105 - 129-142
Front Mount 60-75 - 81-102
Flame Arrestor to Carburetor - 65-80 7-9

Oil Filter One, Turn After Contact

Sender, Oil Pressure 10-14 - 14-19
Sender, Water Temperature 18-22 - 24-30
Spark Plugs 10-15 - 14-20
Engi.~/e.g 4-35
Type - No. of Cylinder ............................. 90° V - 8

Bore and Stroke - 5.0 FL ........................... 4.00 in. x 3.00 in.
Bore and Stroke - 5.8 FL ........................... 4.00 in. x 3.50 in.
Piston Displacement- 5.0 FL ........................ 302 Cu. In. (5.0 Liter)
Piston Displacement- 5.8 FL ........................ 351 Cu. In. (5.8 Liter)
Cylinder No.{front to rear - starboard) ................. 1- 2- 3- 4
Cylinder No.(front to rear - port) ..................... 5- 6- 7 - 8
Firing Order .................................... 1 - 3 - 7- 2- 6- 5- 4- 8
Compression Ratio - 5.0 FL ......................... 8.4:1
Compression Ratio - 5.8 FL ......................... 8.3:1
Fuel System - 5.0 FL .............................. Mechanical pump; Holley 2 BBL.
FueJ System - 5.8 FL .............................. Mechanical pump; Holley 4 BBL.
Thermostat Opens at ............................. 160° F
Full Throttle Operating Range ....................... 4000-4400 RPM
Cylinder Head:
Combustion ChamberVolume (cc) - 5.0 FL .......... 67.5-70.5

Combustion ChamberVolume (cc) - 5.8 FL .......... 63.4-66.4
Valve Guide Bore Diameter ...................... 0.3433-0.3443in.
Valve Seat Width
Intake and Exhaust ........................ 0.060-0.080 in.
Valve Seat Angle - Intake and Exhaust ............. °45
Valve Seat Runout - Maximum ................... 0.0020 in.
Valve Arrangement (Front to Rear)
Right .................................. I-E-kE-I-E-I-E
Left ................................... E-I-E-I-E-m-E-I
Gasket Surface Flatness ........................ 0.003 inch in any 6 inches
or 0.006 inch overall
Gasket Surface Finish RMS* ..................... 60-150
* RMS- Root Mean Square
Valve Rocker Arms, PushRod and Lifters:
Rocker Arm Lift Ratio .......................... 1 =61:1

Valve Push Rod Runout - Maximum ............... 0.015 in.
Hydraulic Lifter
Leakdown Rate ........................... 5-50 seconds maximum
measuredat 1As in. plunger travel
with 50 Ibs. load and leak down
fluid in tappet
Hydraulic Lifter
Standard Diameter ........................ 0.8740-0.8745in.
Clearance to Bore ......................... 0.0007-0.0027 in.
Service Limit ............................ 0.005 in.
EngineSpecifications Cont.
Valve Rocker Arms, Push Rod and Lifters Cont:
Hydraulic Lifter Collapsed Gap

5.0 FL
Allowable ............................... 0.071-0.193in.
Desired ................................. 0.096-0.165in.
5.8 FL
Allowable ............................... 0.098-0.1!;)8in.
Desired ................................. 0.123-0.173in,
Valves:
Valve Stem Diameter

Intake .................................. 0.3416-0.:3423in.
Exhaust ................................ 0.3411-0.:3418in.
Valve Face Angle .............................. °
44
Valve Stem to Valve Guide Clearance
Intake .................................. 0.0010-0.0027in.
Exhaust ................................ 0,0015-0.0032in.
Wear Limit .............................. 0.0055 in.
Valve Head Diameter
Intake - 5.0 FL ............................ 1.770-1.7!;)4in.
Intake - 5.8 FL ............................ 1.837-1.847in.
Exhaust- 5.0 FL .......................... 1.439-1,463in.
Exhaust- 5.8 FL .......................... 1.837-1.847in.
Valve Face Runout (Maximum) ................... 0.0020 in,
Valve Face Runout (Maximum) ................... 0.0020 in,
Valve Spring Free Length - Approximate
intake - 5.0 FL ............................ 2.06 in.
intake - 5.8 FL ............................ 2.056 in.
Exhaust - 5.0 FL .......................... 1.86 in.
Exhaust - 5.8 FL .......................... 1.877in.
Valve Spring Out-of-Square
Maximum ............................... ~’~ (0.078)in.
Valve Spring Pressure - Lbs. at Specified Length
intake- All Models ........................ 78+4 Ibs. @1.78 in.
intake - 5.0 FL ............................ 204-+10Ibs. @1.33 in.
Untake - 5.8 FL ............................ 218-+10Ibs. @1.33 in.
Exhaust - All Models ...................... 75-+4 Ibs. @1.60 in.
Exhaust All models ....................... 205---10 Ibs. @1.15
Service Limit ............................ 10% Pressure Loss
@Spec. Length
Valve Spring AssembledHeight - Pad to Retainer
intake .................................. 1.18 in.
Exhaust ................................ 1.60 in.
Camshaft and Bearings:
Camshaft Journal Diameter Standard

No. 1 Bearing ............................ 2.0805-2.0815in.
No. 2 Bearing ............................. 2.0655-2.0665in.
No. 3 Bearing ............................ 2.0505-2.0515in.
No. 4 Bearing ............................ 2.0355-2.0365in.
No. 5 Bearing ............................ 2.0205-2.0215in.
Engine Specifications Cont .....
Camshaftand BearingsCont:
CamshaftJournal to Bearing Clearance ............ 0.001-0.003in.

ServiceLimit - 0.006in.
Camshaft End Play ............................ 0.001.0.007in.
CamshaftLobeLift
5.0 FL
Intake .................................. 0.2600in.
Exhaust ................................ 0.2780in.
5.8 FL
Intake .................................. 0.2780in.
Exhaust ................................ 0.2830in.
MaximumAllowable Lobe Lift Loss ............... 0.005in.

Bearing Inside Diameter
Bearing No. 1 ............................ 2.0825-2.0835
in.
Bearing No. 2 ............................ 2.0675-2.0685
in.
Bearing No. 3 ............................ 2.0525-2.0535
in.
Bearing No. 4 ............................ 2.0375-2.0385
in.
Bearing No. 5 ............................ 2.0225-2.0235
in.
Camshaft Journal
MaximumRunout T.i.R.** .................. 0o005in.
CamshaftBearing Location
No. 1 Bearing ............................ 0.0050-0.0200
in.*
Timing Chain Deflection - Maximum............... 0.500in.
* Distancein inchesthat the front edgeof the bearingis
installed toward the rear from the front face of the
cylinder block.
** Total indicated Reading
CrankshaftMain Bearings:
Journal Clearance
5.0 FL- No. 1 Bearing
Desired ................................. 0.0001-0.0015in.
Allowable ............................... 0.0001.0.0020in.
5.0 FL- All others
Desired ................................. 0.0005-0.0015in.
Allowable ............................... 0.0005.0.0024in.
5.8 FL
Desired ................................. 0.0008-0.0015
in.
Allowable ............................... 0.0008-0.0026
in.
Wall Thickness
5.0 FL - No. 1 Bearing ........................ 0.0961-0.0966
in,
All Others ............................... 0.0957-0.0962
in.
5.8 FL- No. 1 Bearing ........................ 0.0957-0.0960
in.
All Others ............................... 0.0957-0.0962
in.
C~ankshaft and Flywheel:
Main Bearing Journal Diameter

5.0 FL .................................. 2.2482-2.2490in.
5.8 FL .................................. 2.9994-3.0002in.
Main Bearing Journal Out-of-Round Max ........... 0.0006 in.
Maximum Runout T.I.R.** .................. 0.002
Taper Limit .................................. 0.0004 per in.
Surface Finish Maximum ....................... 12 RMS
Connecting Rod Journal Diameter
5.0 FL .................................. 2.1228-2.1236in.
5.8 FL .................................. 2.3103-2.3’111in.
Connecting Rod Journal Out-of-Round
Maximum ............................... 0.0006 per in.
Connecting Rod Journal Taper
Maximum ............................... 0.0006 per in.
Surface Finish Limit ........................... 12 RMS
Thrust Bearing Journal Length ................... 1.137-1.139in.
Main Bearing Journal Thrust
Face Runout Limit ........................ 0.001
Face Finish .............................. 25 Front 20 Rear RMS
Crankshaft to Rear Face of Block Runout T.I.R.**
Maximum ............................... 0.005 in.
Crankshaft End Play Clearance .................... 0.004-0.0013in.
Service Limit - 0.012 in. max.
** Total Indicated Reading
G~nnecting Rod:
Piston Pin Bore i.D. - Standard .................... 0.9096-0.9112in.

Bearing Bore Diameter
5.0 FL ................................... 2.2390-2.2398in.
5.8 FL ................................... 2.4265-2.4273in.
Bearing Bore Out-of Round and Taper ............... 0.0004 in.
Connecting Rod Length - Center to Center
5.0 FL ................................... 5.0885-5.0915in.
5.8 FL .................................. 5.9545-5.9575in.
Twist Total Difference - Maximum................. 0.024 in.
Bend Total Difference - Maximum.................. 0.012 in.*
Rod Assembled to Crankshaft
Side Clearance ............................ 0.010-0.020in.
Service Limit - 0.023 in.
* Pin, bushing and crankshaft bearing bore must be

parallel, and in the samevertical plane, within the speck
lied total difference at ends of an 8-inch long bar mea-
sured 4 inches on each side of rod.
EngineSpecifications Cont. - - --
Connecting Rod Bearings:
Bearing to Crankshaft Clearance

Allowable ............................... 0.0008-0.0025in,
Desired ................................. 0.0008-0.0015in,
Wall Thickness - Standard .................. 0.0572-0.0577in,
0.002 Undersize .......................... 0.0582-0.0587in.
Pistons:
sPiston Diameter
Coded Red
5.0 FL .................................. 3.9984-3.9990in.
5.8 FL .................................. 3.9978-3,9984in.
Coded Blue
5.0 FL .................................. 3.9996-4.0002 in.
5.8 FL .................................. 3.9990-3.9960 in,
0.003 Oversize
5.0 FL .................................. 4.0020-4.0026 in.
5.8 FL .................................. 4,0014-4.0020 in.
Piston to Cylinder Bore Clearance ................. 0.0018-0.0026 in.
Piston Pin Bore Diameter ....................... 0.9124-0.9127 in.
Ring Groove Width, Compression
5.0 FL
Top .................................... 0.060-0.061 in.
Bottom ................................. 0.060-0.061 in.
Oil Ring ................................ 0.1587-0.1597 in.
5.8 FL
Top .................................... 0.080-0.081 in.
Bottom ................................. 0.080-0.081 in.
OiJ Ring ................................ 0,1880-0.1890 in.
Measuredat the piston pin bore centerline at 90° to the pin
Piston Pin:
Piston Pin diameter - Standard ................... 0.9120-09123in.

0.001 Oversize ........................... 0.9130-0.9133 in.
0,002 Oversize ........................... 0,9140-0,9143 in.
Piston Pin Length ............................. 3.010-3.040 in.
Piston Pin to Piston Clearance
5.0 FL .................................. 0.0002-0.0004 in.
5.8 FL .................................. 0.0003-0.0005 in,
Piston Pin to Connecting Rod Bushing Clearance ..... interference Fit
4-40 Ertgine/eng
Engine Specifications Cont. ---
Piston Rings:
5.0 FL
Top Compression Ring Width ................. 0.0577-0.0587in.
Bottom Compression Ring Width .............. 0.0577-0.0587in.
5.8 FL
Top Compression Ring Width ................. 0°077-0.078in.
Bottom Compression Ring Width .............. 0.077-0.07t3in.
Top Compression Ring Side Clearance .............. 0.002-0.004in.
Bottom Compression Ring Side Clearance ........... 0.002-0.004in.
Service Limit ................................. 0.002 max, increase
in total clearance
Oil Ring Side Cmearance ......................... Snug
Top Compression Ring Gap ....................... 0.010-0.020in.
Bottom Compression Ring Gap ................... 0.010-0.020in.
Oim Ring (Steel Rail) Gap ........................ 0.015-0o055in.
Cylinder Block:
Cylinder Bore Diameter

5.0 FL .................................. 4.0004-4.0052 in.
5.8 FL .................................. 4.0000-4.0048 in.
Maximum Out-of-Round ........................ 0.0015 in.
Maximum Taper .............................. 0.001 in.
Crankshaft to Rear Face of Block Runout
T.I.R. Maximum .......................... 0.005 in.
Lifter Bore Diameter ........................... 0.8752-0.8767in.
Main Bearing Bore Diameter
5.0 FL .................................. 2.4412-2.4420in.
5.8 FL .................................. 3.1922-3.1930in.
Distributor Shaft Bearing Bore Diameter
5.0 FL .................................. 0.4525-0.4541in.
5.8 FL .................................. 0.5155-0,51171 in.
Head Gasket Surface Flatness .................... O.003in. in any 6 in.
or 0.006 in. overall
Head Gasket Surface Finish RMS** ................ 60-150
Cylinder Bore Surface Finish RMS** ............... 18-38
** RMS- Root Mean Square
Oil Pump:
Relief Valve Spring Tension (Lbs. @Specified Length)

5.0 FL .................................. 10.6-12.2 @1.704 in.
5.8 FL .................................. 18.2-20.2 @2.49 in.
Driveshaft to Housing Bearing Clearance ........... 0.0015-0.0030in.
Relief Valve Clearance .......................... 0.0015-0.0030in.
Rotor Assembly End Clearance ................... 0.001-0.004in.
Outer Race to Housing Clearance (Radial) ........... 0,001-0.013in.
NOTES
4-42
Section 5
5.0 Fi, 5.8 Fi andFSi
Tableof Conteni:s
Circulating PumpReplacement........................... 5-6

Core Plugs ........................................... 5-23
Crankshaft Rear Oil Seal ............................... 5-18
Cylinder Head.......................................... 5-9
Camshaft Lobe Lift ................................... 5-24
Compression Test ................................... 5-25
PCVSystem .......................................... 5-26
Engine Coupler Replacement ........................... 5-32
Engine Specifications .................................. 5-36
Exhaust (Flapper) Valve Replacement.................... 5-31
Exhaust Hose and intermediate Pipe Replacement......... 5-30
Exhaust Manifold Replacement........................... 5-5
Front Cover and Timing Chain ........................... 5-12
Front Engine Mounts ................................... 5-27
Height Adjustment ................................... 5-29
Front Oil Seal ......................................... 5-14
High-Rise Exhaust Elbow Replacement................... 5-29
Intake Manifold ......................................... 5-3
Oil Pan ............................................... 5-15
Oil Pump............................................. 5-16
Torque Specifications .................................. 5-34
Valve Clearance Check ................................. 5-21
Valve Lifter ........................................... 5-22
Valve Rocker Arm and Cover ............................ 5-19
Valve Spring, Retainer and Stem Seal .................... 5-11
Safety Warnings
Beforeworkingon anypart of the engine, readthe section called Safetyat the
endof this manual.
Unlessinstructed otherwise, alwaysdisconnect the battery cables from the
battery before workingon electrical systemto preventpossible sparks or arc-
ing in the enginecompartment.
Before starting engine after repair or maintenanceprocedures,alwaysmake
sure ,engine compartmentis free of fuel vaporsto prevent possible fire and
explosion.
care to avoid getting hands,fingers or clothing caughtin the alternator, power
steering pump,supply pump,and circulating pumpbelts, pulleys and other
movingparts.
Engine/eng 5-1
Materials Required
Cleaning solvent
DuraPlus Synthetic Motor Oil
Loctite primer or equivalent
Loctite or equivalent
Scotch-Grip Rubber Adhesive
RTVSiRicone Rubber Sealant
OTCTools Required
T58L-101-APilot Bearing Puller
T58P-6316-D Damper Remover
T59L-100-BPilot Bearing Puller
T61 P-6019-B Cover Alignment Tool
T65P-6701-AOil Seal Installer
"F70L-6500-ALifter Puller
T70P-6049-A Valve Spring Compressor
rToP-6B070-ASeal Installer
TTOP-6B070-B Seal Remover
T71P-6513-B Hydraulic Lifter Compressor
T74P-6666-A Plug Wire Remover
T77L-9533-B Slide HammerTool
T79T-6316-A DamperInstaller
T82L-6701-AOil Seal installer
Order from:
OTCDivision of SPXCorporation
655 Eisenhower Dr.
Owatonna, Minnesota 55060
Phone: 1-800-533-0492
or
1-800-533-5338
5-2 Engine/eng
intake Manifold
Removal
"1. Refer to Upperintake Manifold Remova!in the Fuel Systems

Workshop Manual
2. Removethe two screws securing thermostat housing adapter

to intake manifold.
3. Removeattaching bolts, and remove intake manifold.
If necessary to pry manifold awayfrom cylinder heads, do

not damagegasket sealing surfaces.
4. Removeand discard intake manifold gaskets and seals.
Cleaning
Removeall gasket material from the machined surfaces of the

manifold. Clean the manifold in a suitable solvent and dry it with
compressedair.
Inspection
Inspect the manifold for cracks, damagedgasket surfaces, or

other defects that would makeit unfit for further service. Replace
all studs that are stripped or otherwise damaged. Removeall
filings and foreign matter that mayhave entered the manifold as
a result of repairs.
|nstailation
1. Clean mating surfaces of intake manifold, cylinder head%and

cylinder block. Use a solvent such as Ford Spot Remover(B7A-
19521-A), Cleaning solvent or similar degreasing agent.
Engine/eng 5-3
2. Apply a 1/s in. diameter bead of silicone rubber sealer ~)
(C3AZ-19562-Aor B) in and along the joint, the full width of the
cylinder block seal mounting surface (~) (four corners) as shown.
[~ 3. Install the cylinder head to manifold gaskets ©, and the

front and rear intake manifold to cylinder block seals ~). Apply
1A~in. bead of sealer (~) at the outer end of each intake manifold
seal for the full width of the seal.
This sealer sets up within 15 minutesafter application, so

assembly should proceed promptly.
4. Carefully lower intake manifold into position. Whenintake

manifold is in place, run finger around seal area to be sure seals
are in place. If seals have shifted, removemanifold and reposition
seals.
[~ 5. Be sure intake manifold gaskets are properly aligned, then

install attaching bolts. Tighten snugly to manifold, then tighten
bolts in recommendedsequence to proper torque. Repeat torque
sequence, tightening bolts again to original torque value. Be-
cause the center manifold bolts becomeloose, re-torque mani-
fold bolts seasonally.
@ DR2215
6. Install thermostat housing and adaptor assembly on intake
manifold.
7. Refer to Upperintake ManifoldInstallation in the Fuel Systems

Workshop Manual.
8. Makesure engine compartment is free of fuel vapors. Start

f
Front
engine and checkfor fuel leaks. Checkand adjust ignition timing.
Checkengine for cooling leaks.
[~ 9. After engine reaches normal operating temperature, re-

®,,
tighten manifold bolts and nuts to proper torque in correct
sequence.
32349

32354 32355 32357
Exhaust Manifold Replacement

Removal
r3-~ 1. Loosen six hose clamps (~ holding exhaust hoses to
exhaust elbow (~).
[~ 2. Lubricate lower hose and exhaust pipe with a soapy’water

solution, and slide hose downonto pipe.
3. Removeexhaust elbow from high-rise elbow hose. 32345
4. Starboard Only: Removescrews securing ECAto high-rise

elbow.
ET~ 5. Removethe four screws ® securing high-rise elbow O.

Removethe elbow and discard gasket.
L-~ 6. Loosen clamp and pull water hose off front of mani;fold.
7. Pull spark plug leads off spark plugs. Mark plug wires to ensure
correct firing order.
Eg~ 8. Unscrew eight Iocknuts and lock washers holding mani- 32359
fold to mounting studs. Pull manifold off studs.
9, Removeand discard exhaust manifold gasket.
32356
32358
Eng~ne/eng 5-5
InstaHatior|
[~ 1. Install a new exhaust manifold gasket. Gasket ports must
completely align with exhaust openings.
Gasket can be correctly installed in only one position, if

improperly installed, gasket will block off part of each exhaust
port and/or block access to spark pUugs.
[~] 2. Slide manifold onto studs. Attach lock washers and

Iocknuts, and tighten Iocknuts to 20-26 ft. Ibs. (27-35 N-m).
25924A
3. Coat a new gasket with Gasket Sealing Compound and place it
on manifold. Install high-rise elbow and tighten screws to 12-18
ft. Ibs. (16-24 N-m}. Starboard Only: Attach ECAto high-rise
elbow.
I~ 4. Attach water hose to nipple at front of manifold and
tighten clamp.
5. Attach spark plug wires to plugs. Makesure firing order is

correct.
EEl 6. Lubricate upper (large diameter) outside surface of ex-

25923
haust elbow with a soapy water solution, and push elbow into
high-rise elbow hose until it seats.
[~ 7. Lubricate lower end of exhaust elbow and slide lower

hose up onto elbow. Position hose so that it equally covers elbow
and exhaust pipe.
Z~ DE] 8. Install the six hose clamps and tighten them securely.
Run engine and check for exhaust leaks.
Circulating PumpReplacement
15527
Removal
1. Drain all water from engine block.
2. Loosen the circulating pump pulley bolts, but don’t

removethem at this time. Note, belt tension will keep the pump
from turning while bolts are removed.
3. Release tension on the alternator and power steering

pump belts, then remove them.
4. Unscrewthe pulley bolts, and smidethe pulley offthe circulating

pump hub. 15545
5. Removethe two power steering bracket bouts.
Z~ Safety Related 5-6 Engine/eng

15546 15547 25921
[1-~ 6. Removebrace from alternator bracket to power steering

pump.
[~ 7. RemoveTorx head bolt ~ and spacer and remove power

steering pump.
L-~ 8. Removealternator brace from circulating pumpby remov-

ing bolt and mockwasher.
~’J 9. Loosen hose damp, and pull large hose off circulating
pump. 25920
10. Take out alternator bracket bolts. Removealternator and

disconnect electrical leads at back of alternator. Set alternator
aside.
J~] 11. Removeall pump mounting bolts. Lightly strike pump

with soft hammerto free it from the mounting gasket. Take off
pump, then remove and discard gasket.
installation
1. Thoroughly clean gasket surface on block. Coat both sides of a

15550
new gasket with Gasket Sealing Compoundand position it on
block, Carefully align bolt holes and water passages.
[~ 2, install circulating pump. Screw in all bolts except those
that attach the alternator and power steering pump brackets.
Tighten bolts to 1:.L18 ft. Ibs. (16-24 N-m).
15658
15657
En,~ine/eng 5-7
15529 15531
[~ 3. Push marge water hose onto pump inlet and tighten clamp
securely.
4. Place spacer and Torx head bolt behind rear power

steering pump bracket and secure to block. Attach two power
steering pumpbracket screws and lock washers.
5. Attach the alternator and alternator bracket to the circunat-

ing pumpwith screws, lock washers and flat washers. Tighten the
screws to 18-20 ft. Ibs. (24-27 N.m).
25921
6. Attach electrical leads to back of alternator.
7. Attach aUternator brace to circulating pumpcover. Do not

tighten pivot bolt at this time.
[~ 8. Attach power steering pumpbrace to alternator bracket

with screw and lock washer.
[~ 9. Align the pulley and pumphub screw holes, then slide the
pulley onto the pump. Install the screws and lock washers and
tighten them to 14-20 ft. Ibs. (19-27 N.m).
15528
10. nnstall the power steering pumpbelt and position it in the
innermost pulley grooves. Install the alternator belt in the next
outer groove.
The two belts are different lengths. The power steering

pumpbelt is longer and goes on first.
11. Tension both belts as recommended;see General Information

section. Tighten all power steering and alternator bracket bolts
securely.
12. Run engine and check for water leaks.

15527
5-8 Engine/eng
Cylinder Head
Removal
1. Completelydrain cooling systemto ensureno water remainsin
the intake manifold, cylinder heads, exhaustmanifolds, hosesor
block.
2. Disconnect the spark plug leads at the plugs. Removethe
exhaustmanifolds, then spark plugs.
3. Removethe upper and lower intake manifolds. See Upper
Intake Manifold Removalin the F-uei SystemService Manual.See DR4858
IntakeManifoldin this chapter.

4. Removeany components, brackets or clamps that may be
attached to the front or rear of the cylinder heads. Note their
®
position so that they can be properlyreinstalled.
5. Remove
the rocker armcovers. Discard the old gaskets.
[~ 6. Loosenthe rocker armbolts so that the rocker armsmaybe
rotated. Removethe push rods in sequenceso they can be in- ®
stalledin their original positions. ___]
7. 5.0 Uter Only: Removeand inspect cylinder headbolts.
Retainstandardheadbolts (~); they can be reused.Discan~"torque
to yield" headbolts (~); replace themwith new"torque to yield"
headbolts. Lift the headoff the block. Discardheadgasket.
8. 5.8 Liter Only: Remove

the cylinder headattachingbolts andlift
the headoff the block. Discardheadgasket.
Installation
r~ 1. Cleanthe cylinder head,intake manifold, rocker armcovers

and cylinder block gasket surfaces. If the headwasremovedfor a
cylinder headgasket replacement,checkflatness of the headand
block gasket surfaces. Surface mustnot deviate morethan 0.003
in. (0,076 mm)inany 6 in. (152,4 mm)area, and .006 in. (0,152
ram)overall.
2. A specially treated compositiongasket is used. Do riot apply
sealer to a compos~on gasket. Position the newheadgasket over
the alignmentdowels.Place the headon the block andinsert the
attachingbolts.
Eng~ne/eng 5-9
[~ 3. Thecylinder headbolts are tightened in two steps for all
5.8 liter engines,andin either twoor three steps(torqueto yield
method}for the 5.0 liter enginedependingon whichtype head
bolts are used.Followthe illustrated torquepattern, andtighten
as follows:
~WARNING- Donot reinstall torqueto yield headbolts. Torque
to yield headbolts mustbe replacedoncethey are
removed.
¯ 5.0 LiterEngineswith torqueto yield bolts: DR4860
Step 1. 25-35ft. lb. (33,8 - 47,4 Nm)

Step2. 45-55 ft. lb. (61,0- 74,5 Nm)
Step3. TurnalUbolts in sequenceadditional 85 o _
95° (¼ turn} 4
¯ 5.0 Uter Engineswith standardhex headbolts:
Step 1. 55-65ft. lb. (74,6 - 88,2 Nm}
Step 2. 65-72ft. lb. (88,2 - 97,6 Nm}
e 5.8 Uter Engines:
Step 1. 95-105 ft. lb. (128,8- 142,4 Nm}
Step 2. 105-112ft. lb. (142,4- 151,9 Nm)
4. Cleanthe pushrods in solvent. Blowout the oil passage
in the
pushrods with air. Checkthe endsfor nicks, groves, roughness
or excessivewear. Visually checkpushrods for run-out or with
a dial indicator. Replacepushrod if run-out exceeds0.015 in.
(0,381 ram)at any point. Donot attempt to straightenandreuse
pushrods.
5. Lubricate the rocker armendof pushrod with FordMultipur-
pose GreaseDOAZ-19584-AA or equivalent, and install themin
DR2599
their original positions.
6. Lubricate the valve stemendswith Ford MultipurposeGrease
DOAZ-19584-AA or equivalent.
7. Lubricate the rocker armsand fulcrum seats with Ford

Multipurpose GreaseDOAZ-19584-AA or equivalent. Install
the rocker armsfollowing the procedureunderValve Rocker
ArmInstallation.
8. Clean the rocker arm cover gasket surfaces. Secure new
gasketsin the covers with gasket sealer to ensureproper hole
alignment.Unstall the covers; tighten the mountingscrewsto 36-
60 in. lb. (4-6 Nm).
9. Install the intake manifold.SeeIntake Manifoldin this chap-
ter.
10. Install any components,brackets, or clampsthat werere-
moved.
11. install spark plugs, andthe exhaustmanifolds,then connect
the spark plug leads.
5-10 E.gi~/e.~
Valve Spring, Retainer and Stern Seal \
Removal
Broken valve springs, or damagedvalve stem seals and retainers,

may be replaced without removing the cylinder head, provided
damageto the valve or valve seat has not occurred.
’1. Removerocker arm cover.
2. Removethe applicable spark plug and bring the piston to the

top of the bore to prevent accidental loss of the valve into the DR4861
cyi inder.
:3. Removethe rocker arm fulcrum bolts, fulcrum seats, rocker

arms and push rods from the applicable cylinder.
4. install an air line with an adapter in the spark plug hole and
apply air pressure to the cylinder. Failure of the air pressure to
hoJdthe valve in the closed position is an indication of valve seat
damage,and requires removal of the cylinder head.
5. Install the fulcrum bolt and position Valve Spring Com-

pressor Tool T70P-6049-Aor equivalent as shown. Compressthe DR4862
valve spring and removethe retainer locks, spring retainer, sleeve
and valve spring.
6= Removeand discard the valve stem seal.

[~ If air pressure has forced the piston to the bottom of the
cylinder, any removal of air pressure will allow the valve to fall
into the cylinder. A rubber band, tape or string wrappedaround
the end of the vaJve stemwill prevent this condition and will still
allow enoughtravel to check the valve.
7. inspect the valve stem for damage.Rotate the valve and check
the stem tip for eccentric movementduring rotation. Move the
valve up and down through normal travel in the valve guide and
check the stem for interference, if the vaJve has been damaged,
it’H be necessary to removethe cylinder head.
installation
1. if the condition ,of the valve stemproved satisfactory, lubricate

the valve stem with the recommendedengine oU. Hold the valve
in the closed position and apply air pressure within the cylinder.
E4~2. install a newvalve stemseal on the valve guide. Seall must

be bottomedon guide. Place the spring in position over the valve,
and install the spring retainer and sleeve. Compressthe valve
spring and install the spring retainer [ocks. Removethe compres-
sor tool and fulcrum bolt.
Engine/eng 5-’1 1
3. Lubricate the upper push rod ends with Ford Multi-Purpose
Grease DOAZ-19584-AA or equivalent, and install the push rod.
Apply the samegrease to the tip of the valve stem.

lent to the rocker arms and fulcrum. Install the rocker arms,
fulcrum and fulcrum bolts. Tighten the bolts to 18-25 ft. Ibs. (24-34
N.m).
5. Turn off the air and removethe air line and adapter. Install the
spark plug and connect the plug wire.
DR4863
6. install the rocker arm cover using new gaskets; follow the
procedure under Rocker Armand Cover Installation,
Front Cover and Timing Chain

Removal
1. Refer to Circulating PumpRemovalsection. Perform aln steps

except removal of the pump. Leave it attached to the front cover.
2. Remove the crankshaft pulley. Unscrew the damper

attaching bolt and washer. Attach DamperRemoverT58P-6316-D
or equivalent, and pull vibration damperoff crankshaft°
3. Removethe oil pan-to-cylinder block front cover attaching

bolts. Use a thin-bladed knife to cut the oil pan gasket flush with
the cylinder block face prior to separating the cover from the
block.
4. Removethe cylinder front cover and circunating pumpas an

assembly. Discard the front cover gasket.
5. Checkthe timing chain deflection, if deflection exceeds0.500

in. (12,7 ram), replace the chain and sprockets.
5" 1 2 Engine/eng
[3 6. Crank the engine until the timing marks on the sprockets
are positioned as shown.
7. Removethe camshaft sprocket cap screw, washers and fuel

pumpeccentric. Slide both sprockets and the timing cha;in for-
ward, and remove them as an assembmy.
installation
~2~ 1. Position the sprockets and the timing chain on the cam-
shaft. Be sure the timing marks on the sprockets are positioned as
shown. DR4864
[3~ 2. Install the fuel pump eccentric, washers and camshaft

sprocket cap screw. Tighten the sprocket cap screw to 40-45 ft.
Ibs. (55-61 N.m).
3. Clean the cylinder front cover, oil pan and the cylinder block
gasket surfaces. Clean the oil pan gasket surface where the oil
pan and front cover fasten.
install a newoil seal following procedures under Front Oi:l Seal

Remova|and JnstaJiation.
DR4865
4. Lubricate the timing chain and sprockets with heavy engine oil.
5. Coat the gasket surface of the oil pane with sealer. Cut and
position the requh’ed newgasket on the oil pan and apply sealer
at the corners. Install the pan sealer as required. Coat the gasket
surfaces of the block and cover with Ford Perfect Seal Sealing
CompoundB5A-199554-A (ESR-M18P2-A} or equivalent, and po-
sition a newgasket on the block.
6. Position the cylinder front cover on the cylinder block. Usecare

wheninstalling the cover to avoid seal damageor possible gasket
rnislocation.
DR4886
F=~-3
L~=~_J7. Install the cylinder front cover-to-seal alignment using
F¥ont Cover Aligner Tool T61P-6019-B or equivalent.
8. at maybe necessary to force the cover downwardto slightly

compress the pan gasket. This operation can be facilitated by
vising a suitable tool at the front cover attaching hole Jocal:ions.
9. Coat the threads of the attaching screws with Ford Perfect Seal
Sealing CompoundB5A-19554-A (ESR-M18P2-A) or equivalent
atnd install the screws. While pushing in on the alignmenll tool,
tiighten the oHpan-to-cover attaching screwsto 9-11 ft. Ibs. 113-14
N-m). Tighten the cover-to-cylinder block mounting screws to
9-11 ft. Ibs. (13-14 N-m). Removethe alignment tool.
10. Apply Ford Multi-Purpose Grease DOAZ-19584-AA or equiva-

hub to prevent damage to the seal and to the front of the
crankshaft for damperinstallation.
E~,~i.~/~.g 5-13
[i] 11. Line up the crankshaft vibration damperkeywaywith the
key on the crankshaft. Install the vibration damperon the crank-
shaft using Damper Remover/Replacer Tool l’79T-6316-A or
equivalent. Install the cap screw and washer. Tighten the screw to
70-90 ft. Ibs. (95-322 N-m). Install the crankshaft pulley.
12. Completethe remaining steps under Circulating Pumpinstal-

lation.
13. Operate the engine at a fast idle to bring the engine up to \

operation temperature. Checkand adjust ignition timing to speci-
fications in Electrica|/|gnJtion Workshop Manualunder initial DR4867
Timing Set Procedure.
Front Oil Seal

Removal
1. Removethe crankshaft pulley from the vibration damper.

Removethe damper attaching screw and washer, install the
puller on the crankshaft vibration damperand removethe vibra-
tion damper.
[]~ 2. Place the Front Cover Seal Remover I’70P-6B070-B or DR4868

equivalent onto the front cover plate over the front seal as shown.
Tighten the two through-bolts to force the seal puller under the
seal flange.
3. Alternately tighten the four puller bolts one-half turn at a time

as shownto pull the oil seal from the front cover.
installation
~] 1. Coat a new front cover plate oil seal with Ford Multi-
Purpose Grease DOAZ-19584-AA or equivalent. Place the front oin
seal onto Front Cover Seal Replacer T70P-OB070-A or equivalent.
DR4869
Place the sleeve and seal onto the end of the crankshaft and push
it toward the engine until the seal starts into the front cover.
[T~ 2. Place the installation screw, washer and nut onto the end
of the crankshaft. Threadthe nut against the washerand installer
sleeve to force the seal into the front cover plate. Removethe
installation tool from the crankshaft.

hub to prevent damageto the seal. Apply a white lead and oil
mixture to the front of the crankshaft for damperinstallation.
4. Line up the crankshaft vibration damperkeywaywith the key on

the crankshaft, install the vibration damperon the crankshaft.
Install the cap screw and washer. Tighten the screw to 70-90 ft.
Ibs. (95-122 N-m). Install the crank pulley. Makesure the pulley
bottomed on the damper pilot.
Oil Pan
Removal
1. Removeengine from boat following procedures in Engine

Removaland installation section found elsewhere in this, work-
shop manual.
2. Drain the crankcase. Unscrewthe dipstick tube.
3. Removethe oil pan attaching bolts and removethe pan braces

and pan.
4. Refer to cleaning and inspection procedures. Checkthe gasket

surface for damagecaused by overtightened bolts. Straighten the
surface as required to restore original flatness.
Cleaning
Scrape any dirt or metal particles from inside of pan. Scrape all
old gasket material from the gasket surface. Washpan in a solvent
and dry it thoroughly.
Inspection
Checkthe pan for cracks, holes, damageddrain plug threads, or a

damagedgasket surface.
Inspect for damage(uneven surface) at the bolt holes caused

overtorquing mounting bolts. Straighten surfaces as required.
Repair any damage,or replace the pan if repairs cannot be, made
satisfactorily.
Ilnstallation
14~ 1. Clean the gasket surfaces of block and oil pan. Coat the
block surface and oil pan gasket surface with oil-resistant sealer.
Position oil pan gasket on cylinder block.
14-~ 2. Hold the oil pan in place against block and place par= brace
against pan. Install a bolt finger tight on eachside of oil pan to
hold it in place, then install the remainingbolts. Tighten th,e bolts
Fromthe center outward in each direction. Tighten 1/4-20 bolts to
’9-11 ft. Ibs. (13-14N-m). Tighten¥1~-18bolts to 9-11 ft. Ibs. (13-14
N.m).
15-~ 3. Install dipstick tube fitting to pan; leave screw loose.

Orient fitting and attach dipstick tube. Thentighten both fitting
screw and flare nut to 15-18 ft. lbs. (20-24 N-m). DR2673
,4. Fill engine to proper level with recommended

engine oil.
!5. install engine into boat following procedures in Engine Remov-

a| and installation section. Start engine and check for leaks.
1
31576
Oil Pump
Removal

Removaland Installation section.
2. Removethe oil pan and related parts following the procedure

under Oi| Pan Removal.
[~ 3. Removeoil pump inlet tube and screen assembly.
DR4591
[~ 4. Unscrew oil pump mounting screws. Remove pump and

intermediate driveshaft.
I
Disassembly
1. Removethe four screws and washers securing the oim pump

cover to the oil pump, then oil pumpcover.
2. Removeoil pumpouter rotor and rotor shaft assembly from the

oil pump housing.
3. Remove the cotter pin that secures the relief valve plug in the
2 DR45g0
oil pump housing. To remove the plug, drilm a small hone and
insert a self-tapping screwin the relief valve plug. Use pliers to
removeplug from oil pumphousing. Use care to prevent the loss
of the relief valve spring.
4. Removespring and relief valve from oil pumphousing.
Cleaning
Washall parts in solvent and dry them thoroughly with com-

pressed air. Use a brush to clean the inside of the pumphousing
and the pressure relief valve chamber. Ensure all dirt and metal
particles are removed.
inspection
1. Refer to Specifications for clearances and service limits.
2. Check the inside of the pumphousing and the outer race and
rotor for damageor excessive wear.
3. Check the mating surface of the pumpcover for wear. If the

cover mating surface is worn, scored or grooved, replace the
cover.
32364
~] 4. Rest rotor assembly on fiat surface. Measuretip clearance

with a feeler gauge. Tip clearance must not exceed0.004 in. (0,10
ram).
[~ 5. With the rotor assembly installed in the housing, measure

the outer race to housing clearance ~). Your feeler gauge reading
must be 0.001-0.013 in. (0,03-0,33 ram).
5-16
r~ 6. Place a straight edge (~) over the rotor assembly and the
housing. Measurethe clearance (rotor end play) ©, between the
:straight edge and the rotor and outer race. Your reading must be
0.001-0.005in. (0,03-0,13 ram).
7. Check the driveshaft to housing bearing clearance by measur-

iing the O.D. of the shaft and I.D. of the housing bearing. Correct
clearance is 0.0015-0.0029in. (0,04-0,07 mm).
8. if the pumpfails either Step 4, 5, 6 or 7, replace the oil pump

,assembly. The outer race, shaft and rotor are replaceable only as
,an assembly.
9. Inspect the relief valve spring for a collapsed orworn condition.

,Checkthe relief valve spring tension.
©
e 302 cu. in. (5.0 liter) engines:1.74 in. (44,2 mm)length
with a 10.6-12.2 lb. (4,80-5,53 kg) load. DR1841
o 351 cu. in. (5.8 liter) engines:2.49 in. (63,2 mm)length

with a 18.2-20.2 lb. (8,25-9,16 kg) load.
If the spring tension is not within specifications, and/or spring is

worn or damaged, replace the spring. Check the relief valve
piston for scores and free operation in bore.
The internal componentsof the oil pumpare not serviced.

if any component is out of specifications, the pumpassembly
must be replaced.
Assembly
1. Install relief valve, spring and relief valve plug in oil pump
housing. Press plug inward until it seats, then install the cotter
pin.
2. install outer rotor and rotor shaft in housing. Be sure that

identification markon outer rotor is on the sameside as identifica-
tion mark on inner rotor. Fill the housing with engine oil for
priming purposes.
3. Install the cover plate and tighten the four screwsto 72-120in.
Ibs. (8,1-13,6 N-m).
Installation
1. Primeoil pumpby filling pumpinlet port with engine oil. Rotate

pumpshaft to distribute oil within pumpbody.
2. Position intermediate driveshaft into distributor socket. With

,,;eat firmly seated in distributor socket, the stop on the shaft
should touch roof of crankcase. Removeshaft and position stop
as necessary.
EEl [~ 3. With stop properly positioned, insert intermediate
driveshaft (~) into oil pump. install pumpand shaft as an assem-
bly. Do not attemptto force pump into position if it will not seat
readily. The drive hex maybe misaligned with the distributor
shaft. Rotate intermediate driveshaft to align. Tighten oil pump
mountingscrews (~) to 22-32 ft. Ibs. (30-43 N-m).
~] 4. Clean and install oil pumpinter tube and screen assembly

using a new gasket. Tighten mounting screws © to 10-15 ft. Ibs.
(14-20 N-m). Attach oil pumptube to engine block and tighten nut
@to 22-32 ft. Ibs. (30-43 N-m).
DR4590
5. install oil pan and related parts as outlined under Oil Pan
installation.
Crankshaft Rear Oil Seal

All models have a one piece crankshaft rear oil seal. This
complete seal is replaced without removing crankshaft.
Removal

Removaland installation section. DR4591
2. Removestarter motor.
#
3. Removeflywheel housing, coupling, flywheel and cover. FRONT OF ENGINE
4. Using a sharp awl, punch one hole into the seal metal surface
between the lip and engine bmock.
5. Screw in the threaded end of Snide HammerTool "I-/7L-9533-B

or equivalent. Use the slide hammerto remove the seal. Use
caution to avoid scratching or damagingthe oil seal surface.
installation
1. Lubricate newseal with engine oil.
~] 2. 302 cu, in. (5.0 liter) engines:Position oil seal with seal lip
facing forward on rear Oil Seal Installer T82L-6701-Aor equiva-
lent. Position seal and tool on rear of the engine. Alternate bolt
tightening to properly seat seal The rear face of seal must be
within 0.005 in. (0,127 ram) of rear face of block.
EEl 351 cu. in. (5.8 liter} engines: Start seal with seal lip facing
forward and install it with the rear Oil Seal Replacer tool T65P-
6701-Aor equivalent. Keeptool straight with centerline of crank- DR1860
shaft and instalJ seal until tool contacts cylinder block surface.
FRONT OF ENGINE
DR25~3
5-18 Engme/er~g
[~ Removethe tool and inspect the seal to ensure it was not
damagedduring installation.
3. anstall flywhee~ cover, flywheel, coupling and housing.
4o install starter motor.
5. install engine into boat following procedures in Engine Remov-

al and installation section.
Valve RockerArmand Cover

Removal
1. Disconnect spark plug wires from spark plugs by grasping,

twisting and pulMing molded cap only, using Spark Plug Wire
Remover"F74P-6666-A or equivalent.
2. Removethe exhaust manifold.
3= Removethe valve rocker arm cover(s).
4. Removevalve rocker arm bolt (~, fulcrum ®,rocker arm ~)

and fulcrum guide ®.
inspection - Rocker Arm
if the pad at valve end of rocker arm has a groovedradius, repmace

rocker arm. Do not attempt to true this surface by grinding.
inspection - PushRod
Check ends of push rods for nicks, grooves, roughness or exces-

sive wear.
"The push rods can be visually checkedfor straightness while they

are installed in the engine by rotating them with the valve closed.
’They also can be checked with a dial indicator for a maximum
irunout of 0.015 ill. (0,38 ram). if the pushrod is visibly bent, it
should be replaced.

Ilent to the top of the valve stems, the rocker arm and fulcrum
seats, and upper ,ends of push rods.
DR25~
NoteJ Thefollowing procedurewill placethe lifter on a flat of the
camshaft,not on a portion of the lobe to allow easyinstallation of
the rocker arms.
[~ 2. Position No. 1 piston on TDCat the end of compression

stroke, Position @,andinstall rocker arm, fulcrum, fulcrum guide
andbolt on the following valves:

®
¯ No. 8 Intake, No. 7 Exhaust DR1845
r~ 3. Rotate crankshaft to Position ®, 180° from TDC(~, and (~ TDC

° from (~)
install rocker arm, fulcrum, funcrumguide andbolt on the following ® 180
valves: © 270° from ~)

[~ 4. Rotate crankshaft to Position ©, 270° from Position @,and

install rocker arm,fulcrum, andbolt on the following valves:

5. Be sure that the fulcrumbaseis inserted in its slot on the

cylinder headbeforetightening the fulcrumbolts. Tightenful-
crumbolt to 18-25ft. Ibs. (24-34 N.m).Check
valveclearancefol-
lowing proceduresunder Valve ClearanceCheckingProcedures
6. Clean and inspect gasket surfaces of engine block and valve

cover(s). Rnspectvalve cover gasket sealing surface(s) for damage
anddistortion due to overtighting of bolts. Place a newgasketin
cover(s), makingsure that tabs of gasket engagenotchesprovided
in cover(s).
7. Position cover(s) on cylinder headgasketsurface(s). Make

gasketseatsevenlyall aroundhead.Install bolts. Thecoveris tight-
enedin two steps. Tighten bolts to 36--60in. Ibs. (4-6 N.m). Wait
two minutes, then tighten bolts to the samespecifications. If the
starboard cover wasremoved,install PCVvalve.
8. Install exhaustmanifold. Connectspark plug wires. Start engine

and checkfor leaks.
Valve Clearance Check
Thevalve arrangement is on the port bankis E-I-E-I-E-I-E-I andon

the starboardbankis I-E-I-E-I-E-I-E.
Valvestemto valve rocker armclearanceshouldbe within specifi-

cations with the hydrauliclifter completelycollapsed.Repeated valve
reconditioningoperations(valve and/orvalve seat refacing) or valve
seat recession wear causedby (extended use) will decreasethe
clearanceto the point that, if not compensated for, the hydraulic
valve lifter will ceaseto function andthe valve will be held open.
Notej Theuse of positive stop rocker armbolts eliminates the
needto adjust the; valve clearance. However,to obtain the speci-
lied valve clearance,it is importantthat all valve components
be in
a serviceablecondition andinstalled andtightened properly.
To determine whether newservice parts are necessary, makethe

following check:
~_~1. Removethe PURPLE wire from the "1" terminal of the
starter assist solenoidso the enginedoesnot start. Install an
auxiliary starter switch. Crankthe engine with the ignition
switch OFFuntil the No. 1 piston is on TDCafter the compres-
sion stroke.
I~ 2. With the crankshaftin the positions designatedin Steps2, 3

and 4, position the Hydraulic Lifter Compressor Tool T71P-6513-B
@or equivalent on the rocker arm. Slowly apply pressureto bleed
downthe hydraulic lifter until the plungeris completelyboltomed.
Holdthe lifter in this position andcheckthe available clearance
betweenthe rocker armandthe valve stemtip with a feeler’ gauge
DR1845
[3~ 3. With the No. 1 piston onTDC

at the end of the compression (~)TDC
stroke as shownin Position @,checkthe following valves: ® 180° from (~)
© 270° from (~)
[~ 4. After checkingthe spacingon these valves, rotate the crank-
.,;haft to Position (~, 180° from TDC@, then checkthe following
vamves:

l.-’~in~ ~ Safety Related 5-21

L__U5o After checkingspacingon these valves, rotate the crank-
shaft to Position @,270° from Position @,andcheckthe following
valves:

ClearanceSpecifications:
5.0 Modems
Allowable: 0.071-0.193in. (1,8-4,9 ram) ~) TDC

Desirable: 0.096-0.165in. (2,4-4,2 mm) ® 180° from (~)
@ 270° from ~)
5.8 Models
Allowable: 0.098--0.198in. (2,5--5,0 mm)

Desirable: 0.123--0.173in. (3,1-4,4 ram)
Valve Lifter
Thefollowing procedureis applicablefor removingoneor all of the

valve lifters. Beforereplacinga hydraulic valvelifter for noisyop-
eration, be sure the noise is not causedby impropervalve clear-
ance or by worn rocker armsand/or push rods.
Dirt, gumor varnish depositsandair bubblesin the lubricating oil

cancausehydraulic valve lifter failure or malfunction.
Dirt, gumand varnish can keep a check valve from seating and
causea loss of hydraulic pressure. An openvalve disc will cause
the plungerto force oil backinto valve lifter reservoir during time
pushrod is beinglifted to force valve fromits seat.
Air bubblesin the lubricating systemcan be causedby too high or

too low an oil level. Air mayalso be drawninto the lubricating sys-
temthroughan openingin a damaged oil pick-up tube. Air in an oil
lifter cancausea loss of pressureto lifter.
Removal
1. Remove intake manifold and related parts following procedures

under intake Manifold.
2. Removethe valve rocker arm covers. Loosenthe rocker arm

bolts andturn rocker armsto one side.
3. Remove the push rods in sequenceso they can be nstalled in

their original positions.
4. Using Hydraulic TappetPuller T70L-6500-A or equivalent, re-

movelifters andplacethemin a rack so that they canby installed in
their original bores.
5-22 Engine/eng
Cleaning
Thoroughly clean all the parts in cleaning solvent and wipe them
with a clean, lint-free cloth.
inspection
inspect the parts and discard the entire lifter assemblyif any part
showspitting, scoring, galling or evidence of non-rotation. Re-
place entire assemblyif plunger is not free in the body.
Checkfor freeness of operation by pressing downon the push rod

cup. Thelifters can also be checkedwith a hydraulic tester to test
leak-down rate. Follow tester manufacturer’s instructions to per-
form test.
Installation
1. Clean outside of valve lifters. Lifters and bores are to be

lubricated with specified engine oil before installation. Install
lifters in their original bores. Checkany newlifter for free fit in
bore to which it has been installed.

lent to valve stem tips and push rod ends. Install push rods in
original positions.
,’3. Lubricate rocker arms and fulcrum seats with Ford Multi-
Purpose Grease DOAZ-19584-AAor equivalent.
4. Position the rocker arms over the push rods and tighten the
bolts following the procedure under Valve Rocker Arm Installa-
tion. Adjust valve clearance following procedure under Valve
Clearance Check.
5. install rocker arm covers following procedure under Rocker

Armand Cover Installation.
6. Install intake manifold and related parts following the pro-

cedures under intake Nianifold.
Core Plugs
Removal
To removea large core plug, drill a 1/2 in. (12,7 mm)hole in center
of plug and remove with an Clutch Pilot Bearing Puller Tool
T59L-100-Band T58L-101-Aor pry it out with a large drift punch.
Ona small core plug, drill a 1/4 in. (6,37 ram) hole in center of plug
and pry it out with a small pin punch. Cleanand inspect plug bore.
Prior to installing a core plug, plug bore should be inspected for

any damagethat would interfere with proper sealing of plug. if
bore is damaged it will be necessaryto true surface by bori:ng for
the next specified oversize plug. Oversize (OS} plugs are identi-
fied by OSstampedin flat located on the cup side of plug.
Ughtly coat plug and/or bore with an oil resistant (oil galley)
water-resistant (cooling jacket) sealer, and install it following
procedure for cup-type or expansion-type below:
installation - Cup-Type
~] Cup-type core plugs (~) are installed with flanged edge

outward. The maximumdiameter of this plug is located at outer
edgeof flange. The flange on cup-type plugs flare outward with
largest diameter at outer (sealing) edge
it is imperative to push plug into machinedbore by using a DR1847

properly designed tool Under no circumstances is plug to be
driven into bore using a tool that contacts flange. This method
will damagethe sealing edge and will result in leakage and/or
plug blow out.
The flanged (trailing) edge must be below chamfered edge of

bore to effectively seal plugged bore.
If core plug replacing too{ has a depth seating surface, do not seat
tool against a non-machined(casting) surface.
Installation - Expansion-Type
DR1848
~-~ Expansion-type core plugs <~) are installed with flanged edge
inward. The maximumdiameter of this plug is located at base of
flange with flange (~) flaring inward.
It is imperative to pushor drive plug into machinedbore using a

properly designed tool. Under no circumstances is plug to be
driven using a tool that contacts crowned portion of plug. This
method will expand plug prior to installation and may damage
plug and/or plug bore.
Wheninstalling plug, the trailing (maximumdiameter) must

below chamfered edge of bore to effectively seal bore.
if core replacing tool has a depth seating surface, do not seat tool
against a non-machined(casting) surface.
Camshaft Lobe Uft
Checklift ofeachlobein consecutive order, and make a note of

the readings.
1. Removevalve rocker arm cover.
2. Removevalve rocker arm. Install a solid, tappet-type push rod

in push rod bore of camshaft lobe to be checked, or use the
adapter for ball end push rods.
5-24 E~Jne~
E~ 3. Makesure push rod (~) is seated against camshaftlobe.
Install a dial indicator so that actuatingpoint ® of indicator is in
pushrod socket(er the indicator ball socketadapteris on endof
the push rod) and in sameplane as push rod movement.
4. Removespark plugs.
5. Connectan auxiliary starter switch in starting circuit. Crank

enginewith ignition switch OFF.Bump crankshaft over until lifter
is on basecircle of camshaft
lobe. At this point, pushrod will be in
its lowestposition.
6. Zerodial indicator. Continueto rotate crankshaftslowly until DR1849
pushrod is in fully raised position.
7. Compare
total lift recordedon dial indicator with specifica-
tions:
302cu. in. (5.0 liter) and351cu. in. (5.8 liter):
Intake- 0.278in. (’7,061 ram)

Exhaust- 0.283 in. (7,188 ram}
Maximum Allowable Loss - 0.005 in. (0,13 ram)
8. To checkaccuracyof original indicator reading, continue to
rotate crankshaftuntil indicator readsZERO. If lift on any lobe is
belowspecified wearlimits, camshaftandvalve lifters operating
on the wornlobe(s) mustbe replacedas well as any lifter showing
pitting or havinga contact face wornflat or concave.
9. Remove dial indicator andauxiliary starter switch, install rocker
arm. NOTE: Do not rotate crankshaft until hydraulic liftere; have
had a chanceto bleed down. To do otherwise maycauseserious
valve damage.Manuallybleeding downlifters will reducewaiting
time,
10. Install the valve rocker armcover.
11. Install sparkplugs.
Compression
Test
1. Be sure crankcaseoil is at proper level and of correct
viscosity. Makesure that battery is properly charged. Operate
engine for a minimum of 30 minutesat 1200RPM,or until engine
is at normaloperatingtemperature.Turnignition switch off; place
the shift control in NEUTRAL,and removethe shorting balr from
the double wire SPOUT connector at ignition coil.
2. Remove all spark plugs.
3. install a compression
gaugein No. 1 cylinder.
e,~,,o ,~ Safety Related 5-25

L~ 4. install an auxiliary starter switch in starting circuit. Using
auxiliary starter switch, crank engine (with ignition switch OFF)
at Jeast five compression strokes and record highest reading.
Note approximate number of compression strokes required to
obtain highest reading.
5. Repeat test on each cylinder. Crank engine same number of
compressionstrokes as was required to obtain highest reading on
No. 1 cylinder.
Test Conclusion
The indicated compression pressures are considered normal if

Jowest reading cylinder is within 75%of the highest. Refer to the
following example:
Highest Reading: 140 PSI (8703 kPa)

75%: 105 PSi (5027 kPa)
Jn this example, any cylinder reading less than 105 PSi (5027 kPa)
indicates an improperly seated vaRve, or worn or broken piston
rings.
af one or more cylinders read low, squirt approximately one

tablespoon of engine oil on top of the pistons in low reading
cyJinders. Repeat compression pressure check on these cyl|nders.
1. Jf compressionimproves considerabJy, piston rings are at fault.
2. If compressiondoes not improve, valves are sticking or seating

poorly or valve guides are leaking.
3. if two adjacent cylinders indicate low compression pressures

and squirting oil on pistons does not increase compression, the
cause may be a cylinder head gasket leak between cylinders.
Engine oil and/Or coolant in the cylinders could result from this
problem.
Positive Closed-TypeVentilation System

A malfunctioning closed crankcase ventilation system may be
indicated by loping or rough engine idle. Do not attempt to
compensatefor this idle condition by disconnecting the crank-
case ventilation system and making carburetor adjustments. The
removalof the crankcaseventilation systemfrom the engine wii|
adversely affect fuel economy and engine ventilation with resul-
tant shortening of engine life. To determine whether loping or
rough idle condition is caused by a malfunctioning crankcase
ventilation system, perform the folJowing tests.
L~ Safety Related 5-26

1. RemovePCVvalve from its mounting, but leave vacuuminlet
side connected to hose. If the valve is functioning properly and
not plugged, a hissing noise will be heard as air passes through
valve. A strong vacuumwill be felt whena finger is placed over
valve inlet. Check for vacuum leaks in hose line and at all
connections.
2. Reinstall PCVvalve, then removecrankcase air inlet hose at

flame arrestor connection. Loosely hold a small piece of stiff
paper (such as a 3 × 5 memocard or parts tag card) over opening
at end of inlet hose. After a minute or so, (to allow crankcase
pressure to lower) the piece of paper should be sucked against
hose opening with a noticeable force.
RemovePCV valve from its mounting and shake it. A metallic

clicking noise should be heard, indicating that valve parl;s are
free, and not sticking.
if ventilation systempassesthese two tests, it can be considered

functionally OK,and no further service is required. If it fails either
test, replace PCVvalve and repeat Engine idling Test.
ff systemstill does not pass test, perform the folmowing:
¯ Removeand clean crankcase filter located under the PCV

valve grommet.
o Clean ventiEation system hoses and all passages to

induction system in accordance with established pro-
cedures.
Servicing PCVValve
31588
Do not attempt to clean crankcaseventilation regulator valve, it

should be replacecL Clean crankcase ventilation system connec-
tion(s} on intake manifold by probing with a fle×ible wire or bottle
brush. CUeanhoses, tubes and associated hardware with a low-
volatility, petroleum-base solvent and dry with compressedair.
Front Engine Mounts

Removal
E~ ~ 1. Prior to removing a front mount, measure distance

between large washer (~ and flat (~) on upper mount bracket. 31582
Record this dimension so mount can be correctly reassembled.

E2-~ 2. Removethe top nut and washers from the mount.
[3~ 3. Removethe two lag screws © and washers securing the

mount.
31580
Engine/eng 5-27
~4. Lift enginewith 1500 lb. (680 kg) minimum
capacity hoist
to allow remova!of front mount.
E~ 5. Removetwo mountbracket-to-block screws and lock wash-

ers @and removebracket.
Disassembly
~] Hold mount bolt with a socket, and remove the two

nuts and disassemble mount. 31578
Assembly
~-1 Place small washer® on the mountbolt and insert bolt up

through mount. Install large washer ® and secure with nut @.
Torqueto 60-75ft. Ibs. (81-102N.m).
Installation
E~ Fully seat front enginemountadjusting bolts into the front en-

gine mount ®. Dt~558
,~,CAUTION Bolt hole @is usedfor 5.8 liter blocks only, bolt hole
O is for the 5.0 liter blocks only. Theenginewill be damaged if
these positions are usedincorrectly.
Note] The head of support screw and mating contact point on
block mustbe free of paint.
r’T] 2. Sprayboth mountbracket-to-blockscrewswith Loctite primer

or equivalent and allow to air dry. Apply Loctite or equivalent to
both screws. Attach bracket to engine with two screwsand wash- 11983
ers. Tightenscrewsto 32---40ft. Ibs. (43-54N-m).
E~ 3. Place a 0.005 in. (0.13 mm)feeler gaugebetweenthe en-

gine block and the enginemountadjusting bolt. Adjust the engine
mountadjustingbolt in or out until a resistanceis felt on the feeler
gauge.
4. Mark the engine mountadjusting bolt head. Back the engine

mountadjustingbolt out exactly onehalf (1/2) turn.
[~ 4. Install upper inner nut and washer ® on mountassembly DR4529A

andplace bolt into bracket, then install top nut andwashers@.
5. Set height adjustment, refer to Height Adjustment.
]/~ Safety Related 5-28 31577

Engine/eng
Height Adjustment
Z~ 1. Lift enginewith a hoist capableof lifting at least 1500 lb.

(B80 kg). Position engineat desired height.
L6~ 2. To changeengine height, tighten or loosen nuts (~) and
as required.
EEl 3. After setting mount position, turn nut (~ up against

underside of engine bracket and hold nut with a wrench. Tighten
top nut (~ to 50-70 ft. lbs. (68-95 N.m).
[~ Any large adjustments to engine height should be fok

h)wed by a check of engine alignment. Failure to check alignment
could result in rapid engine coupler failure.
Remova|
[7~ 1. Loosen two clamps securing upper hose. Lubricate inside
of hose ,with a soapy water solution.
2. Starboard Only: Removescrews securing ECA to high-rise 32696

elbow and set out of the way.
[3 I~ 2. Removefour screws, flat washers and lock wa,shers

mounting high-rise elbow. Use a soft hammerto free the elbow
from the manifold,. Use a twisting motion to pull high-rise elbow
from hose. Removeand discard the manifold gasket.
JnstaJJation
[!~] 1. Thoroughly clean manifold gasket surface ~). Apply
Gasket Sealing Compoundto both sides of a new gasket and
place it on the exhaust manifold.
32687
[~ 2. Lubricate the inside of the exhaust hose with a soapy

water soUution, insert the high-rise elbow into the hose with a
twisting motion, and push it into hose as far as it wilt go,
3. Position high-rise elbow on manifold. Install four screws, flat

washersand lock washers. Tighten screws to 12-18 ft. Ibs. (16-24
N-m). Starboard Only: Attach ECAto high-rise elbow.
4. Slide clamps up onto hose and position them in the two surface
channels. Tighten clamps securely.
32688
I~,,~o~/~0 ~ Safety Related 5-29 32689

32691 32692 32693
Exhaust Hose and Intermediate Pipe

Replacement
Removal
[~ 1o Loosen four clamps ~) attaching lower hose, and slide
clamps off the hose.
~l 2. Lubricate inside of hose, top and bottom, with a soapy

water solution, and slide hose down onto exhaust pipe.
F~ 3. Loosen all clamps on upper hose. Removeintermediate
pipe ® with a twisting motion.
[~] 4. Slide upper hose off high-rise elbow.
[~ 5. Slide lower hose off exhaust Y-pipe.
|nstallation
[-~ ~ Both the upper and lower hoses have a step in the
inside diameter that must face the intermediate pipe.
32695
~] 1. Lubricate inside diameter of lower hose with a soapy
water solution. Slide it all the way onto the exhaust Y-pipe.
[~ 2. Place four clamps on upper hose. Push hose all the way
onto high-rise, elbow. Position clamps in channels at top of hose,
and tighten clamps securely.
F~ 3. Lubricate inside of upper hose. With a twisting motion,
insert intermediate pipe (~) all the way into the upper hose and
position it as shown. Do not attach the hose clamps at this time.
32366
E~ 4. Slide lower hose up until it equally overlaps the intermedi-
ate and exhaust pipes.
ET~ 5. Slide two clamps © onto upper hose. Slide four remaining
clamps (~) onto lower hose. Position clamps in channels and
tighten securely.
Exhaust (Flapper) Valve Replacernent - SX

Models
Removal
6373
1. The exhaust valves are at the upper ends of the exhaust pipes.
Removeadaptor pipes and lower exhaust hoses.
ES~2. Using a small drift or punch ~), push the exhaust valve pin
(~) out of each exhaust pipe.
[~ [~ 3. Remove pin and valve. Push out two rubber bush-

ings.
installation
1. Apply Scotch Grip Rubber Adhesive to two new rubber 6375A

bushings and push into each exhaust pipe.
~1~ ~ 2. Lightly lubricate exhaust valve pin with oil. Position
valve in each exhaust pipe with long side of valve down. Pushpin
through bushing and exhaust vamveuntil flush with both sides of
pipe. Check exhaust valve for freedom of movement.
if the valve is not positioned properly (long mip down}, it

will restrict exhaust flow and fail to prevent water from backing up
into exhaust system. Boat performance could be adversely af-
fected, and major powerhead damagecould occur.
6376
3. install exhaust hoses and adaptor pipes.
6377
5-31 .,8
Engine/eng
Engine Coupler Replacement - SX Models
Removal
if coupler is being replaced due to coupler failure (rubber

coupler.

Remova|and mnstructions, in this manualo
2. Cut tie strap holding flywheel housing drain hose to

starter motor, then remove starter. Removesmall screws along
forward edge of bellhousing plate.
EEl 3. Unscrew outer nut on ground stud, and take off lock
washer and electrical leads. Removeinner nut, lock washer and
washer. Removesimilar ground stud hardware on opposite side
of bnock.
4. Removepower steering cooler. Unscrew remaining flywheel

housing bolts, lock washers and washers. Note position of clamps
so they can be installed in original position.
6675
[~] 5. Loosen belihousing with a soft hammer, and pull off
engine.
6. Unscrewsix nuts and lock washers, then pult coupler off

flywheel.
installation
1. Slide coupler onto crankshaft studs. Install lock washers

and nuts. Use a crowfoot wrenchand tighten nuts to 40-45 ft. Ibs.
(54-61 N-m).
6710
67tZA
~’6--~ 2. Install flywheel housing. Place clampsin their original
positions and attach power steering cooler. Tighten screws to
28-36 ft. Ibs. (38-49 N-m).
L~ 3. Place washer, lock washer and nut on ground stud. Tighten

inner nut to a torque of 20-25 ft. lbs. (27-34 N.m). Attach electrical
leads to ground stud. install lock washer end tighten outer nut
securely. Install ground stud hardwareon opposite side of block.
L~ 4. install small screws along forward edge of bellhousing

plate and tighten to 60-84 in. Ibs. (6,7-9,5 N-m). Install starter
motor and tighten screws to 24-30 ft. Ibs. (33-41 N-m). Attach 6711A
flywheel housing drain hose to starter motor with a tie strap.
5. Install engine in boat following instructions in Engine Removal

and Installation in this manual.
SCREW FT. LBS iN, LBS. N-m

SiZE
No. 6 - 7- 10 0,8- 1
No. 10 2-3 25-35 3-4
No. 12 3-4 35-45 4-5
1/4 5- 7 60 - 80 7- 9
%s 10 - 12 120 - 140 14- 16
% 18 - 20 220 - 240 24- 27
Use a reliable torque wrenchto tighten the parts listed to prevent straining or distorting the parts or
friction which prevents accurate measurement of tightness. It is important that these torque specifica-
Adaptor- Oil Pressure Sender 10-14 - 14-19

Alternator- Bracket to Pump 18-20 - 24-27
Camshaft Sprocket 40-45 - 55-61
Circulating Pump 12-18 - 17-24
Cover, Flywheel Housing 6O-84 6,7-9,5
Cover Plate, Oil Pump 72-120 8-16
Cylinder Block Cover 12-18 17-24
Distributor Clamp 17-25 23-34
Exhaust Elbow 12-18 16-24
Fitting, Oil Withdrawal Tube 15-18 20-24
Flywheel Cover 60-84 6,7-9,5
Front Mount to Block 32-40 43-54
Fuel Pump 18-20 24-27
Intake Manifold 23-25 31-34
Oil Inlet Tube-to-Pump 10-15 14-20
Oil Inlet "PdbeBracket 22-32 30-43
Oil Pan (114 x 20) 9-11 12-15
Oil Pan (5116 x 18) 9-11 12-15
Pulley, Crankshaft 22-32 30-43
Pulley, Circulating Pump 14-20 19-27
Rocker Arm 18-25 24-34
Rocker Arm Cover - 36-60 4-6
Starter Motor 8racket 16-19 22-26
5-34 Engine/eng
TorqueSpecifications- (Cont.)
IFr. US.JCIN.LBS.
1
Raw-water PumpBracket 12-18 - 17-24

Thermostat Housing 12-16 - 16-22
Throttle Body 12-18 - 16-24
Upper Manifold 12-18 - 16-24
Water Outlet Housing 10-15 - 14-20
Connecting Rod
302/5.0 19-24 - 26-33
351/5.8 40-45 - 54-61
Coupler, Engine 40-45 - 54-61
Exhaust Manifold 20-26 - 27-35
Flame Arrestor 30-40 3,4-4,5
Front Mount (top) 50-70 68-95
Vibration Damper 70-90 95-122
Withdrawal Tube to Fitting 15-18 20-24
Cylinder" Head(302/5.0)
Step 1 25-35 33,8-47,4
Step 2 45-55 61,0-74,5
Step 3 Tighten an additional 85°- 95° (1/4 turn)
Cylinder Head(351/5.8)
Step 1 95-105 129-143
Step 2 105-112 - 143-151
Main Bearing Cap
302/5.0 60-70 81-95
351/5.8 95-105 129-142
Oil Filter One"Turn After Contact

Sender, Oil Pressure 10-14 - 14-19
Sender, Water Temperature 18-22 - 24-30
Spark Plugs 10-15 - 1 4-20
E,~,/~, 5-35
Type - No. of Cylinder ............................. 90° V - 8

Bore and Stroke - 302/5.0 .......................... 4.00 in. x 3.00 in.
Bore and Stroke - 351/5.8 .......................... 4.00 in. x 3.50 in.
Piston Displacement - 302/5.0 ....................... 302Cu. In. (5.0 Litre)
Piston Displacement- 351/5.8 ....................... 351Cu. In. (5.8 Litre)
Cylinder No. (front to rear - starboard) ................ 1- 2- 3 - 4
Cylinder No. (front to rear - port) .................... 5- 6- 7- 8
Firing Order .................................... 1 - 3- 7- 2- 6- 5- 4- 8
Compression Ratio - 302/5.0 ........................ 8.5:1
Compression Ratio - 351/5.8 ........................ 8.8:1
Fuel System - 302/5.0 ............................. Electric pump
Fuel System - 351/5.8 ............................. Electric pump
Thermostat Opens at ............................. 160° F
Full Throttle Operating Range - 5.0/5.8 ................ 4200-4600 RPM
Cylinder Head:
Combustion ChamberVolume (cc) - 302/5.0 ......... 60.6-63.6

Combustion Chamber Volume (cc) - 351/5.8 ......... 63.4-66.4
Valve Guide Bore Diameter ...................... 0.3433-0.3443 in.
Valve Seat Width
intake and Exhaust ........................ 0.060-0.080 in.
Valve Seat Angle - Intake and Exhaust ............. °
45
Valve Seat Runout - Maximum ................... 0.0020 in.
Valve Arrangement (Front to Rear)
Right .................................. I-E-I-E-I-E-I-E
Left ................................... E-I-E-I-E-I-E-i
Gasket Surface Flatness ........................ 0.003 inch in any 6 inches
or 0.006 inch overall
Gasket Surface Finish RMS* ..................... 60-150
* RMS- Root Mean Square
Valve Rocker Arms, Push Rod and Ufters:
Rocker Arm Lift Ratio .......................... 1.61:1

Valve Push Rod Runout- Maximum ............... 0.015 in.
Hydraulic Lifter
Leakdown Rate ........................... 5-50 seconds maximum
measuredat V~ein. plunger travel
with 50 Ibs. load and leak down
fluid in tappet
Hydraulic Lifter
Standard Diameter ........................ 0.8740-0.8745in.
Clearance to Bore ......................... 0.0007-0.0027in.
Service Limit ............................ 0.005 in.
Valve Rocker Arms, PushRod and Lifters Cent:
Hydraulic Lifter Collapsed Gap

302/5.0
Allowable ................................ 0.071-0.193 in.
Desired .................................. 0.096-0.165 in.
351/5.8
Allowable ................................ 0.098-0.1913in.
Desired .................................. 0.123-0.173in.
Valves:
Valve Stern Diameter

Intake .................................. 0.34160.3423 in.
Exhaust ................................ 0.3411-0.3418in.
Valve Face Angle .............................. °44
Valve Stem to Valve Guide Clearance
Intake .................................. 0.0010-0.0027in.
Exhaust ................................ 0.0015-0.0032in.
Wear Limit .............................. 0.0055 in.
Valve Head Diameter
Intake - 5.0/5.8 ........................... 1.837-1.847in.
Exhaust - 5.0 ............................ 1.536-1.546in.
Exhaust. - 5.8 ............................ 1.837-1.847in.
Valve Face Runout (Maximum) ................... 0.0020 in.
Valve Spring Free Length - Approximate
intake .................................. 2.056 in.
Exhaust: ................................ 1.877 in.
Valve Spring Out-of-Square
Maximum ............................... ~’~ (0.078)iin.
Valve Spring Pressure - Lbs. at Specified Length
Intake .................................. 78+4 Ibs. @1.78 in.
Intake .................................. 204-+10Ib.¢L @1.15 in.
Exhaust ................................ 75-+4 Ibs. @1.33 in.
Exhaust: ................................ 205-10 Ibm;. @1.15
Service Limit ............................ 10% Pressure Loss
@Spec. Length
Valve Spring AssembledHeight - Pad to Retainer
Intake .................................. 1.78 in.
Exhaust ................................ 1.60 in.
Camshaft and Bearings:
Camshaft Journal Diameter Standard

No. 1 Bearing ............................ 2.0805-2.0815in.
No. 2 Bearing ............................ 2.0655-2.0665in.
No. 3 Bearing ............................ 2.0505-2.05115in.
No. 4 Bearing ............................ 2.0355-2.03:65in.
No. 5 Bearing ............................ 2.0205-2.02’15in.
Engine Specifications Cont. 7
Camshaft and Bearings Cont:
Camshaft Journal to Bearing Clearance ............ 0.001-0.003in.

Camshaft End Play ............................ 0.001-0.007in.
Camshaft Lobe Lift
302/5.0
Intake .................................. 0.2600 in.
Exhaust ................................ 0.2780 in.
351/5.8
Intake .................................. 0.2780 in.
Exhaust ................................ 0.2830 in.
Maximum Allowable Lobe Lift Loss ............... 0.005 in.

Bearing Inside Diameter
Bearing No. 1 ............................ 2.0825-2.0835in.
Bearing No. 2 ............................ 2.0675-2.0685in.
Bearing No. 3 ............................ 2°0525-2.0535in.
Bearing No. 4 ............................ 2.0375-2.0385in.
Bearing No. 5 ............................ 2.0225-2.0235in.
Camshaft Journal
Maximum Runout TJ.R.** .................. 0.005 in.
Camshaft Bearing Location
No. 1 Bearing ............................ 0.0050-0.0200 in.*
Timing Chain Deflection - Maximum............... 0.500 in.
* Distance in inches that the front edge of the bearing is

installed toward the rear from the front face of the
cylinder block.
~’* Total Indicated Reading
Crankshaft Main Bearings:
Journal Clearance
302/5.0- No. 1 Bearing
Desired ................................. 0.0001-0.0015in.
Allowable ............................... 0.0001-0.0020in.
302/5.0 -Alt others
Desired ................................. 0.0005-0.0015in.
Allowable ............................... 0.0005-0.0024 in.
351/5.8
Desired ................................. 0.0008-0.0015 in.
Allowable ............................... 0.0008-0.0026 in.
Wall Thickness
302/5.0- No. 1 Bearing ....................... 0.0961-0.0966 in.
All Others ............................... 0.0957-0.0962in.
351/5.8- No. 1 Bearing ....................... 0.0957-0.0960in.
All Others ............................... 0.0957-0.0962in.
EngineSpecifications Cont,
Crankshaft and Fiywheeh
Main Bearing Journal Diameter

302/5.0 ................................. 2.2482-2.2490in.
351/5.8 ................................. 2.9994-3.0002in.
Main Bearing Journal Out-of-Round Max ........... 0.0006 in.
Maximum Runout T.I.R. ~ .................. 0.002
Taper Limit .................................. 0.0004 per in.
Surface Finish Maximum ....................... 12 RMS
Connecting Rod Journal Diameter
302/5.0 ................................. 2.1228-2.1236in.
351/5.8 ................................. 2.3103-2.3:111in.
Connecting Rod Journal Out-of-Round
Maximum ............................... 0.0006 per in.
Connecting Rod Journal Taper
Maximum ............................... 0.0006pea" in.
Surface Finish Limit ........................... 12 RMS
Thrust Bearing Journal Length ................... 1.137-1.139in.
Main Bearing Journal Thrust
Face Runout Limit ........................ 0.001
Face Finish .............................. 25 Front 20 Rear RMS
Crankshaft to Rear Face of Block Runout T.i.R.**
Maximum ............................... 0.005 in.
Crankshaft End Play Clearance ................... 0.004-0.008in.
Service Limit- 0.012 in. max.
*~ Total Indicated Reading
Connecting Rod:
Piston Pin Bore I.D. - Standard ................... 0.9096-0.9112in.

Bearing Bore Diameter
302/5.0 ................................. 2.2390-2.2:398in.
351/5.8 ................................. 2.4265-2.4,273in.
Bearing Bore Out-of Round and Taper .............. 0.0004 in.
Connecting Rod Length - Center to Center
302/5.0 ................................. 5.0885-5.0915in.
351/5.8 .................................. 5.9545-5.9575in.
Twist Total Difference - Maximum.................. 0.024 in.
Bend Total Difference - Maximum.................. ~
0.012 in.
Rod Assembled to Crankshaft
Side Clearance ............................ 0.010-0.020in.
Service Limit- 0.023 in.
Pin, bushing and crankshaft bearing bore must be

parallel, and in the samevertical plane, within the speci-
fied total difference at ends of an 8-inch long bar mea-
sured 4 inches on each side of rod.
Engine Specifications Cont.
Connecting Rod Bearings:
Bearing to Crankshaft Clearance

Allowable ............................... 0.0008-0.0025in.
Desired ................................. 0.0008-0.0015in.
Wall Thickness - Standard .................. 0.0572-0.0577in.
0.002 Undersize .......................... 0.0582-0.0587in.
Pistons:
Piston Diameter*
Coded Red
302/5.0 ................................. 3.9984-3.9990in.
351/5.8 ................................. 3.9978-3.9984in.
Coded Blue
302/5.0 ................................. 3.9996-4.0002in.
351/5.8 ................................. 3.9990-3.9960in.
0.003 Oversize
302/5.0 ................................. 4.0020-4.0026in.
351/5.8 ................................. 4.0014-4.0020in.
Piston to Cylinder Bore Clearance ................. 0.0018-0.0026in.
Piston Pin Bore Diameter ....................... 0.9124-0.9127in.
Ring Groove Width, Compression
302/5.0
Top .................................... 0.060-0.061 in.
Bottom ................................. 0.060-0.061in.
Oil Ring ................................ 0.1587-0.1597in.
351/5.8
Top .................................... 0.080-0.081in.
Bottom ................................. 0.080-0.081 in.
Oil Ring ................................ 0.1880-0.1890in.
* Measuredat the piston pin bore centerline at 90° to the pin
Piston Pit{:
Piston Pin diameter - Standard ................... 0.9120-09123in.

0.001 Oversize ........................... 0.9130-0.9133 in.
0.002 Oversize ........................... 0.9140-0.9143 in.
Piston Pin Length ............................. 3.010-3.040 in.
Piston Pin to Piston Clearance
302/5.0 ................................. 0.0002-0.0004 in.
351/5.8 ................................. 0.0003-0.0005in.
Piston Pin to Connecting Rod Bushing Clearance ..... interference Fit
Engine Specifications Cont ...........
~lillf~_ _ _.
PistonRings:
302/5.0
Top CompressionRing Width ................ 0.0577-0.0587in.
Bottom CompressionRing Width ............. 0.0577-0.0587in.
351/5.8
Top CompressionRing Width ................ 0.077-0.078in.
Bottom CompressionRing Width ............. 0.077-0.078in.
Top CompressionRing Side Clearance ............. 0.002-0.004in.
Bottom CompressionRing Side Clearance .......... 0.002-0.004in.
Service Limit ................................. 0.002 max. increase
in total clearance
Oil Ring Side Clearance ........................ Snug
Top Compression Ring Gap ...................... 0.010-0.020in.
Bottom Compression Ring Gap ................... 0.010-0.020in.
Oil Ring (Steel Rail) Gap........................ 0.015-0.055in,
CylinderBlock:
Cylinder Bore Diameter

302/5.0 ................................. 4.0004-4.0052 in.
351/5.8 ................................. 4.0000-4.0048 in.
MaximumOut-of-Round ........................ 0.0015in.
MaximumTaper .............................. 0.001in.
Crankshaft to Rear Faceof Block Runout
T.I.R. Maximum.......................... 0.005in.
Lifter Bore Diameter ........................... 0.8752-0.8767
in.
Main Bearing Bore Diameter
302/5.0 ................................. 2.4412-2.4420
in.
351/5.8 ................................. 3.1922-3.1930
in.
Distributor Shaft Bearing Bore Diameter
302/5.0 ................................. 0.4525-0.~1541in.
351/5.8 ................................. 0.5155-0.5171in.
HeadGasket Surface Flatness .................... 0.003in. in any6 in.
or 0.006in. overaln
HeadGasket: Surface Finish RMS**................ 60-150
Cylinder Bore Surface Finish RMS**............... 18-38
** RMS- Root MeanSquare
Off Pump:
Relief Valve :Spring Tension(Lbs. @Specified Length)

302/5.0 ................................. 10.6-12.2@1.704in.
351/5.8 ................................. 18.2-20.2@2.49 in.
Driveshaft to HousingBearing Clearance ........... 0.0015-0.0030 in.
Relief Valve Clearance .......................... 0.0015-0.0030 in.
Rotor Assembly End Clearance ................... 0.001-0.004in.
Outer Raceto HousingClearance(Radial) ........... 0.001-0.013in.
NOTES
5-42
Section 6
7.4, 8.2 GL, Gi andGSi
Table of Contents
Camshaft ................................................. 6-16

Camshaft Lobe Lift, Measuring ............................... 6-21
Circulating Pump........................................... 6-32
Crankshaft ................................................ 6-23
Cylinder Block ............................................. 6-30
Cylinder Head ............................................... 6-9
Engine Specifications ....................................... 6-37
Exhaust Hose and Intermediate Pipe Replacement............. 6-36
Exhaust Manifold Replacement ................................ 6-5
Front Engine Mount Replacement ............................ 6-33
General Motors Tools ......................................... 6-2
High-Rise Exhaust Elbow Replacement ....................... 6-34
Intake Manifold .............................................. 6-3
Lubrication System ......................................... 6-18
Oil Pan ................................................... 6-19
Oil Pump............. . ..................................... 6-20
Oil Seal Replacement, Rear Main Bearing .............. " ....... 6-22
Piston, Ring and Connecting Rod ........................... 6-26
RemoteEngine Oil Filter .................................... 6-19
Timing Chain, Cover and Seal ................................ 8-14
Torque Specifications .......................................
Valve Lifter, Hydraulic .........................................
6-40
6-6
/
Valve Spring and Seal Repair .................................. 6-8
Safety Warnings
Beforeworkingon anypart of the engine,readthe section called Safety at the
endof this manual.
Unlessinstructed otherwise,alwaysdisconnectthe battery cablesfrom the bat-

tery beforeworkingon electrical systemto preventpossiblesparksor arcing in
the engine compartment.
Before starting engine after repair or maintenance procedures,always make

sure enginecompartmentis free of fuel vaporsto preventpossiblefire andex-
plosion.
Whenworkingon an enginethat is runningor being cranked,use extremecare

to avoidgetting hands,fingers or clothingcaug;htin the alternator, powersteer-
ing pump,raw-waterpumpand circulating pumpbelts, pulleys andother moving
parts.
Genera/Motors Tools
Part
item Number

Bearing Puller Set .............................. J-6098
Camshaft Lobe Lift Indicator ...................... J-8520
Carbon Remover ............................... J-8089
Dial Indicator Set ............................... J-5239
Crankshaft Seal/Sprocket installer ................. J-22102
Crankshaft Sprocket Puller ....................... J-1619
Dial Indicator .................................. J-8087
Hydraulic Lifter Remover ...................... J-9290-01
Hydraulic Lifter Remover ....................... J-3049-A
Main Bearing Replacer .......................... J-8080
Pin Remover & Installer ......................... J-24086
Reamer Tool Set ............................. J-5830-02
Ring Compressor ............................... J-8037
Seal Installer ................................. J-35468
Seal instalmer ................................. J-38841
Spring Compressor ........................... J-5892-C
Spring Tester .................................. J-8056
Torsional Damper Puller ....................... J-23523-E
Order Directly from:
Kent-Moore Tool Division

28635 Mound Road
Warren, MI 48092
1-800-345-2233
Price and ordering information is available from Kent-Moore Tool

Division.
Material Required
Kerosene or Equivalent Cleaning Solvent
Volvo Penta DuraPius" Synthetic Motor Oil
Molykote Lubricant
Plastigage (G ree n)
GMSilicone Rubber Sealer
GMEngine Oil Supplement
Volvo Penta Amphenol Crimping Tool P/N 322696
Liquid Neoprene
For additional service information not covered in this manual,

obtain the appropriate Chevrolet Engine WorkshopManual from:
Helm Inc.
P. O. Box 07130
Detroit, MI 48207
6-2 Engine/eng
intake Manifold
Removal
SeeOn-BoardService in the MFIDiagnostic (7.4 Gi, 7.4
GSi) - GMWorkshopManualfor upper intake plenum#7-
stallation.
coolant from both sides of cylinder block andexhaustmanifolds.
[~] 2. Remove
(:over (~) andflame arrestor.
3. Remove
alternator.
[~ 4. Removethermostat housing (~).
[~ 5. Disconnectfuel line (~) at carburetor. Disconnectpurple/

white stripe wire (~ at chokecoil housing.
6. Disconnectthrottle cable at carburetor andanchorblock.
7. Remove main electrical harness from clamps on port side of
manifomd and at front of manifold. Disconnectother ,wire connec=
tions as necessary’.
EEl 8. Removedistributor cap (E) and mark the position

the rotor on the housing. Scribe a line on the distributor hous-
ing and intake manifold for reassemblyin the samepesition.
Removethe distributor.
9. Unscrewattaching bolts, andremoveintake manifold and carbu-
retor as an assembly.
~,CAUTION-
if necessary to pry ma~, take care not to damage
the sealing surfaces.
10. Remove
and discard usedintake manifold gaskets and seals.
Cleaning
Remove all gasket material and clean the sealing surfaces of the
manifold, cylinder block and thermostat housing. Remove exces-
sive carbon deposits from exhaust passages,scale and deposits
from cooling passages.Cleanthe manifoldin a suitable solvent and
dry with compressedair.
inspection
inspect the manifoldfor cracks, damagedgasketsurfaces, or other
defectsthat wouldmakeit unfit for service.
installation
1. Unstall new manifold seals on block, and new gaskets on

cylinder heads. Use only side gaskets having metal inserts
covering the center exhaust passage. Use sealer at water pas-
sages and where seals butt to gaskets.
2. Install intake manifold. Tighten bolts in the sequence

shown. See Torque Specifications at end of section for torque
figure.
Check torque of the intake manifold screws annually. The

center screws can become loose under normal usage.
3. install distributor with rotor and align exactly as markedduring

removal. Install clamp and tighten screw to 25 ft. Ibs. (34 N.m).
NOTE:if engine was cranked while distributor was out, complete
ignition timing procedure must be followed.
4. install distributor cap and high tension leads.
5. Place main wire harness under clamps on port side of manifold

and at front of manifold. Makeother wire connections as neces-
sary.
DR3793
6. Attach throttle cable to carburetor and anchor block.
7. Connectpurple/white stripe wire to choke housing. Attach fuel

line to carburetor.
8. Apply Gasket Sealing Compoundto both sides of a new

thermostat housing gasket and pBaceit on manifold. Place lifting
eye on long bolt, then install and tighten both botts to 12-16 ft.
Ibs. (16-22 N-m}.
9. Install alternator and properly tension belt. Tighten mounting

screws securely.
Z~ 10. Install flame arrestor and tighten nut to 25-35 ft. Ibs.
(2,8-4,0 N.m). Install flamearrestor coverandtighten nut 30-35 ft.
Ibs. (3,4-4,0 N-m).
11. Attach battery cables at battery. Start engine and check

for fuel and water leaks.
Z~ Safety Related 6-4 Englne/eng

!Exhaust Manifold Replacement
Removal
Drain water from respective exhaust manifold before be-

ginning procedure.
1. Removehigh-rise exhaust elbow following procedure under

2. Carefully pull wires off spark plugs.
:3. Loosen hose clamp at front of manifold, and pull off water
hose.
4. Removemanifold attaching screws, nuts and washers. Discard

@
nuts. Removemanifold and discard manifold gasket.
Cleaning
,Clean mating surfaces on manifold and cylinder head. Clean the

"threads on the exhaust manifold bolts.
inspection DR2875
Inspect for cracks. To pressure check manifold, use a fabri-

cated plate (~ as shownand a newelbow gasket (~) to seal water
passage in manifold. Be sure to apply sealer to gasket, install
rubber drain cap to manifold and secure with clamp. Attach a
gear unit pressure tester © (such as Volvo Penta pressure gauge,
P/N 9996398-5)to the water inlet hose. A bushing can be m, ade to
secure pressure tester to hose. With the pressure tester attached
to the manifold, submerge manifold in water. Pressurize the
manifold to 10-15 PSI (22-25 kPa) and check for leaks.
!Installation
18946
1. install a newexhaust manifold gasket.
13~] ~ 2. Install manifold and secure with screws, washers and

new Iocknuts. Tighten nuts to 20-26 ft. Ibs. (27-35 N-m). Tighten
screwsto 24-28 ft. Ibs. (33-38 N-m).
3. Attach water hose to nipple at front of manifold and tighten

clamp.
.4. Attach spark plug wires to plugs. Makesure firing order is

(correct.
18944
5. install high-rise exhaust elbow following procedure under

,~ 6. Start engine and check for water and exhaust leaks.
En~=n~ ~ Safety Related 6-5

HydraulicValve Lifter
CheckingHydraulic Valve Lifter
Whenchecking hydraulic valve lifters, rememberthat grit, sludge,

varnish, or other foreign matter will seriously affect their opera-
tion. if any foreign substance is found in the lifters or engine
where it maybe circulated by the lubrication system, a thorough
cleaning job must be done to avoid a repetition of lifter trouble.
To help prevent lifter trouble, the engineoil and oil filter mustbe
changed as recommendedin General information Section. The
engine oil must be heavy-duty type (for Service SG) and must
also conform to General Motors Standard 6094-M to avoid
detrimental formation of sludge and varnish. We recommend
Volvo Penta DuraPlus" Synthetic Motor Oil. The boat owner
should be specifically advised of these requirements when the
unit is delivered. Faulty valve lifter operation usually appears
under one of the fotlow[ng conditions:
1. RappingNoise Only WhenEngine is Started:
Whenthe engine is stopped, any lifter on a camshaft Jobe is under

pressure of the valve spring; therefore, leak downor escapeof oil
from the nower chambercan occur. Whenthe engine is started, a
few secondsmaybe required to fiml the lifter, particularly in colder
weather, if noise occurs only occasionamly, it maybe considered
normal, requiring no correction, if noise occurs frequentny, how-
ever, checkfor either oil too heavyfor prevaiJing temperatures, or
excessivevarnish in lifters.
2. intermittent RappingNoise:
An intermittent rapping noise that appears and disappears every

few seconds indicates leakage at check bamaseat due to foreign
particles, varnish, or defective surface of checkball or seat.
3. Noise at Idle and LowSpeed:
If one or more valve lifters are noisy at idle speed and up to

approximately 1200 RPM,but quiet at higher speeds, it indicates
excessive leak downrate or faulty checkbale seat or plunger. With
engine idling, lifters with excessive leak down rate may be
spotted by pressing down on each rocker arm above the push rod
with equal pressure. Recondition or replace noisy lifters.
6- 6 Englne/eng
4. GenerallyNoisyat All Speeds:
Check for lowor highoil levelin crankcase. Highoil levelswill bechJrned by

crankshaft andwill forceair bubbles into thelifters. Low oil levelsallowpumpto
pump air at highspeed.Withengineidling, strike eachrockerarmabovethe
pushrodseveralsharpblows witha mallet;if noisedisappears, it indicates
that
foreignmaterialwaskeeping checkball fromseating.Stopengineandplace
lifters oncamshaft basecircle. If thereis lashclearance in anyvalveli~nkage,it
indicatesa stucklifter plunger,wornlifter bodylowerend,or worncamshaft
lobe.
DR3785
5. LoudNoiseat Normal
OperatingTemperature
Only:
J 9290-O1
If a lifter develops a loudnoisewhen the engine is at normaloperating
tem-
,.~rature,butis quietwhen engineis belownormal temperature,
it indicatesan
excessively fast leakdown rateof scoredlifter plunger.Recondition
or replace
lifter.
Removal
{
1. Withair hoseandcloths,cleandirt fromcylinderheads
andadjacent partsto DR3786
,avoidgettingdirt into engine.
It is extremely
important
thatnodirt getsinto the
valve
lifters.
2. Remove
intake manifold.Remove
exhaustmanifolds.
3. Removerockerarmcovers.Donotpry. If coversstick userubbermalletand

strike coverendto jar loose.Loosen
rockerarmnutsandpivot therockerarm
freeof thepushrods.
[~ ~] 4. Remove pushrods. Remove the hydraulic lifters thai require

:serviceoneat a timeandplacethemin anorganizerrack.Thelifters mustbe
installed in the sameborefromwhichthey wereremoved. NOTE: A stuck
hydrauliclifter canberemoved
usingToolJ-3049-A(pliertype)orToolJ-9290-01
(smide hammertype).
15.If less thana complete set of lifters is beingremoved, immediatelydisas-

semble oneor twofor presenceof dirt or varnish.If lifters containdirt or var-
nish,it is advisableto removeall lifters for replacement.Otherwise,
it will be
.,satisfactory
to serviceonlythoselifters thatarenotoperating properly.
r~ 6. Examinethe; camcontactsurfaceat lowerendof lifter body.If this

surfaceis excessivelyworn,galledor otherwise
damaged, discardthelifter
assembly.In this case,alsoexaminethe matingcamshaft lobefor excessive
wearor damage.
L~6. Engineswith roller lifters. Examine the camcontactsurfacefor uneven

wear.Examine
lifters for stuckrollers, fiat spots,pits, missing
or broken
needle
bearings.
Check lefter to barrelclearence for excessiveclearenceor galling.
installation
i
’ NoteBeforeinstallinganynewlifters, coatthebottom
of thelifter or lifter
roller withMolykote
or its equivalent.
Engine/eng 6- 7
1. Install valve lifters in cylinder block. If any newlifters or a new
camshaft has been installed, an additive containing EPlubricant
such as G.M. Engine Oil Supplement must be added to the
crankcaseoil for break-in.
2. Install pushrods onto lifters. Install intake manifold.
3. Pivot rocker arms in place and install rocker arm bolts. Tighten
bolts to 40 ft. Ibs. (54 N-m).
4. Install rocker arm covers, using G.M. Sealer No. 1052289, and
tighten nuts to 115 in. Ibs. (13 N.m).
5. Install exhaust manifold. Start engine and check for oil leaks at
rocker arm covers.
Valve Spring andSeal Repair

Removal
1. Removerocker arm cover.
2. Removespark plug, rocker arm, and push rod on the cylinder(s)

to be serviced.
EEl 3. Install Air Line Adapter tool J=23590to spark plug port and
apply compressedair to hold the valves in place.
~-] 4. Using tool J-5892-C to compressthe valve spring, remove
the valve locks, valve cap and valve spring and damper.
5. Removethe valve stem oil seal.
Installation
1. Install seal over valve stem and seat against head.

DR3796
2. Set the valve spring and damper, valve shield and valve cap in
place. Compressthe spring with toot J-5892-C and instalm oil seal J 5892"C -~
in the lower groove of the stem, making sure the seal is flat and
not twisted. NOTE:A light coat of oil on the seal will help prevent
twisting.
3. Install the valve locks and release the compressortool making

sure the locks seat properly in the upper groove of the valve stem.
NOTE: Grease may be used to hold the locks in place while
releasing the compressor tool
4. Install spark plug and torque to 22 ft. lb. (30 N.m). DR37~
5. Install rocker armcover. Tighten nuts to 115 in. Ibs. (13,0 N-m).
Cylinder Head
Removal
1. Drain water from block and exhaust manifolds. Removeintake

and exhaust manifolds.
2. Removevalve covers and spark pJugs.
3. Loosen rocker arm bolts and turn rocker arms aside. Remove
pushrods. if lifters are to be serviced, removethemat this point.
Otherwise protect the lifters and the camshaft from the entrance
of dirt by covering the area with clean cloths.
4. Removecylinder head bolts, cylinder heads and gasket. Place

cyJinder heads on bench, supporting them at each end on blocks
of wood to prevent damageto gasket faces of heads.
Disassembly
1. Removerocker arm bolts, ball seats and rocker arms.

i[~ 2. Using tool J-8062, compressthe valve springs and remove
the valve keys. Release the compressortool, and removerotators, DR3125
springs and spring dampers, then removeoil seals.
3. Removevalve from bottom of cylinder heads and place them

and their respective valve springs in a rack in their proper
sequenceso they can be assembledin their original positions.
Cleaning
1. Clean aN carbon from combustion chambers and valve

port using tool J-8089.
I~ 2. Thoroughly cJean the valve guides using tool J-8101.

DR3123
3. Clean all carbon and sludge from push rods and rocker’ arms.
4. Clean valve stems and heads on a buffing wheel.
5. Cneancarbon deposits from head gasket mating surfaces.
inspection
1. Inspect the cylinder head for cracks in the exhaust ports,

combustion chambers, or external cracks to the water chamber. DR3124
Engino/eng 6-9
2. Inspect the valves for burned heads, cracked faces or damaged
stems.
[~ 3. Measure valve stem clearance as follows"
a. Clampa dial indicator on one side of the cylinder head

rocker arm cover gasket rail.
b. Locate the indicator so that movementof the valve stem

from side to side (crosswise to the head) will cause
direct movementof the indicator stem. The indicator
stem must contact the side of the valve stem just above DR2101
the valve guide.
c. Drop the valve head about 1As in. (1,57 mm)off the valve
seat.
d. Movethe stem of the valve from side to side using light

pressure to obtain a clearance reading. If clearance
exceedsspecifications, it will be necessaryto reamvalve
guides for oversize valves.
~’~ 4. Checkvalve spring tension with tool J-8056 spring tester.
[~ On all models, springs should be compressed and should

check 74-86 pounds at 1.80 in. (4,57 crn} and 195-215 pounds at
1.40 in. (3,56 cm). Weaksprings affect power and economyand
should be replaced.
Repair
DR3122
1. Valve Guide Bore:
Valves with oversize stems are available for both inlet and
exhaust valves. Refer to your parts catalog for available sizes. Use
the reamer sizes from reamer tool set J-5830-02 to reamthe bores
for new valves.
2. Valve Seats:


contact betweeneach valve and its seat in the head is imperative
away.
6-10 E,~t.~
Several different types of equipmentare available for reseating
valve seats; the =recommendations of the manufacturer of the
properresults.
Regardlessof what type of equipmentis used, however, it is

essential that valve guidesbe free from carbonor dirt to ensure
propercentering of pilot in the guide.
a. lnstall expanding pilot in the valve guide bore and

b. Placeroughingstone or forming stone over pilot andjust
clean up the valve seat. Usea 46° stone for both the inlet
and exhaustvalve seats.
c. Removeroughing stone or forming stone from pilot,

install finishing stoneon pilot andcut just enough
metal
from the seat to provide a smoothfinish.
d. Narrowdownthe valve seats to the proper width for the
intake andexhaust. SeeSpecifications at the endof this
section.
U~°¢Ul°This operationis doneby grinding the port side with a 30

stone to lower seat anda 60° stone to raise seat.
e. Remove ,expandingpilot and clean cylinder headcare-

operations.
[~ [~ Valve seats should be concentric to within 0.002 in.

total indicator reading.
Valvesthat are pitted canbe refacedto the properangle, ensuring

correct relation betweenthe headand stem on a valve refacing
machine.Valve stemswhich showexcessive wear, or valves that
are warpedexcessively should be replaced. Whena valvo head
which is warpedexcessively is refaced, a knife edgewill be
groundon part or all of the valve headdueto the amountof metal
that must be removedto completely reface. Knife edgeslead to
breakage,burning or pre-ignition due to heat localizing on this
knife edge.if the edgeof the valve headis less than l~z in. thick
after grinding, replacethe valve.
Engine/eng 6-11
ao If necessary, dress the valve refacing machine grinding
°wheel to makesure it is smoothand true. Set chuck at 45
b. Clampthe valve stern in the chuck of the machine.
c. Start the grinder and movethe valve head out in line

de Turn the feed screw until the valve head just contacts
wheel. Move valve back and forth across the wheel and
Continue grinding until the valve face is true and smooth

all around valve, ff this makesthe valve thin, the valve
must be replaced as the valve will overheat and burn.
f. Removevalve from chuck and place stem in "V" block.

Feed vaJve squarely against grinding wheel to grind any
pit from rocker arm end of stem. NOTE:Only the extreme
end of the valve stem is hardened to resist wear. Do not
grind end of stem excessively.
g. After cleaning valve face and cylinder head valve seat of

grinding particles, makepencil marks about 1/4 in. apart
across the valve face, pJace the valve in cylinder head
and give the valve one-half turn in each direction while
exerting firm pressure on face of valve.
h. Remove valve and checkface carefully. If all pencil marks

have not been removedat the point of contact with the
valve seat, it will be necessary to repeat the refacing
operation and against recheck for proper seating.
Assembly
Whenreplacing valve springs, refer to the latest parts

catalog for ordering information.
EEl 1. Starting with number 1 cylinder, place the valves in the

designated ports and assemble aim but the seal and locks. Then,
using tool J-5892-C, compressthe spring (E) and install the seal (E)
and locks ©. See that the seal is fiat and not twisted in the valve
stem groove, and that the locks seat properly in the valve stem
groove.
D~795
6-12 Englno/e~
[~ Place valve spring in position with the closed coil end
[2-~ 2. Checkthe installed height of the valve springs, using a
narrow, thin scale cut away at the bottom (~). Measurefrom the
top of the shim, or spring seat, in the headto the top of the. valve
spring shield. Thecorrect installed height is 1 sl/¢4 ___1h2in. (45,64
mm_+0,787 ram) (~).
installation
1. Wipeoff engine block gasket surface and be certain no foreign

material has fallen into the cylinder bores, bolt holes, or the valve
lifter area. it is goodpractice to clean out bolt holes with an air
hose.
This engine has special marine head gaskets. Do not

substitute automotive head gaskets.
47267
2. Install newhead gasket on cylinder block. Dowelsin the. block
will hold the gasket in position. Alwayshandle gaskets carefully to
avoid kinking or damageto the surface treatment of the gaskets.
DO NOTuse any type of sealing material on head gaskets. The
gaskets are coated with a special lacquer to provide a good seal,
once the parts have warmedup. ® ® ® ®
3. Carefully set in place on the engine block dowel pins.
4. Clean and lubricate the head boJts with Gasket Sealing Com-
Z
pound, install bolts.
DR2g05
~] 5. Tighten the head bolts with a torque wrench, in three
progressive steps, following the sequenceshown.
Step 1 - 35 ft. Ibs. (47 N.m)

Step 2 - 65 ft. Ibs. (88 N.m)
Step 3- 85 ft. Ibs. (115 N-m)
[~ Damageto the cylinder block threads can result if bolts are
not lubricated with Gasket Sealing Compound prior to installation
or if the bolts are tightened excessively. Use an accurate ’torque
wrench when installing head bolts and do not overtighten.
Uneven tightening of the cylinder head bolts can distort the
cylinder bores, causing compression loss and excessive oil con-
sumption.
En~i~,,g 6-13
Timing Chain, Cover and Seal
HarmonicBalancer Removal
1. Remove
alternator andpowersteering belts, andcrankshaft pul-
ley.
2. Attach tool J-23523-Eto balancer, and turn puller screwto

removebalancer from crankshaft.
DR357
NoteCoverneednot be removedto pry out and install seal.
3. Pry oil seal out of front of coverusinga large screwdriver.
[~ 4. Steel Covers:Coat seal lips with engine oil. Install new

seal with lip towardinside of cover. Usetool J-35468to drive seal
into position.
E~] 4. AluminumCovers: Coat seal lips with engine oil. Install DR3787
newseal with lip towardinside of cover. Usetool J-22102to drive J 22102
seal into position.
Timing Chain Cover Removal
5. Remove circulating pumppulley, alternator brace, and power

steering pump.
6. Drain cooling systemand removehoseat circulating pump.Dis-

connect temperature sender wire, then removecirculating pump
and discard gaskets.
7. Remove
oil pan. SeeOil Panin this section.
8. Removethe front cover-to-block attaching screws.Remove

front
cover and gasket.
Timing Chain and Sprocket Replacement
[~] 1. Crank engine until "0" markson camshaftand crankshaft

sprockets are in alignment. In this position, engineis timedto
DR3579
fire No. 6 cylinder.
2. Removecamshaftsprocket bolts. Removesprocket and timing

chain together. Sprocketis a slight press-fit for approximately1/8
inch. If sprocket doesnot comeoff easily, a light blow with a I
plastic-faced hammer on the lower edgeof the camshaftsprocket
shoulddislodgeit.
E~ 3. if crank sprocket requires replacement,use a two or three

jaw puller suchas J-1619that pilots on endof crankshaftto pull off
sprocket.
6-14
L~ 4. Install crank sprocket using tool J-22102 to drive it into
place over keyway.
5. Install timing chain on camshaft sprocket. Hold the sprock-

et vertical with the chain hanging below. Align the camand crank
sprocket timing marks, and attach the chain to the crank sprocket.
6. Align dowel in camshaft with dowel hole in sprocket and install

sprocket on camshaft.
Do not hammersprocket onto camshaft. This may loosen

rear camshaft welsh plug. DR3577
7. Draw sprocket onto camshaft using the mounting bolts. Lubri-

care the timing chain with engine oil.
Timing Chain Cover installation
1. Clean gasket surface on block and crankcase front cover’.
2. install new oil pan gasket and oil pan. See Oil Pan in this
section.
3. Coat the gasket with sealer and place in position on cover.

DR3576
Apply a lh inch bead of silicone rubber sealer, Genera/MotorsP/N
1052366(or equivalent) to the joint formed at the oil pain and
cylinder block.
4. Position crankcase front cover over crankshaft. Press cover

downwardagainst oil pan until cover is aligned and installed over
dowel pins on block.
5. Install the front cover-to-block attaching screws.
6. Tighten front cover to block bolts. See TorqueSpecifications at

the end of this section for the torque figure.
24965
Harmonic Baiancer installation
1. Coat machinedouter surface of balancer hub with engine oil.

Align keywayand start balancer onto crankshaft.
[6~ 2. Using appropriate end of tool J-23523-E threaded into
crankshaft, or a large washer and a 7/Is-20 x 4 in. bolt and nut
ti~readed into center hole in crankshaft, tighten nut to seat
harmonic balancer on crankshaft.
ET~ 3. Removeinstalling tool. Install crankshaft pulley and
t!ighten screws securely. Thread 7/16-20 × 2 in. bolt and thick
washer into crankshaft and tighten. See Torque Specifications at
4.. Install circulating pumpand pulley, and tighten screws se-

curely. Attach water hose to pump.
5. Install alternator and power steering pumpbrackets, install
alternator and powersteering belts and adjust tension to specifi-
cations°
Camshaft
Removal
[~ 1. Removedistributor ~). Removeintake manifold and circu-

lating pump.
2. Removerocker arm covers, loosen rocker arms, then remove 28257

push rods and valve lifters.
3. Removecrankshaft pulley, harmonic balancer, timing chain

cover, timing chain and camshaft sprocket.
DE] 4. nnstaHtwo or three ~s-18 x 4 in. bolts in camshaftsprocket

bolt holes and carefully pull out camshaft. Use care not to
damagecamshaft bearings.
The camshaft has five bearings, all with the samejournal diame- DR3796
terof 1.9482 in. to 1.9492 in. These dimensions should be checked
with a micrometer for an out-of-round condition, if the journals
exceed 0.001 in. out-of-round, the camshaft should be replaced.
The camshaft should also be checked for alignment. The best

methodis by use of "V’" blocks and a dial indicator tool J-8520.
The dial indicator will indicate the exact amountthat the camshaft
is out of true. if it is out morethan 0.002 in. dial indicator reading,
the camshaft should be replaced. When checking, the high
reading of the dial indicator indicates the high point of the shaft.
Examinethe camshaft bearings and if any bearing needs replace-
ment, replace all bearings.
Camshaft Bearing Re~ovai
Camshaft bearings can be replaced while engine is disassembled

for overhaul, or without complete disassembly of the engine. To
replace bearings without complete disassembly, remove the
camshaft and crankshaft leaving cylinder heads attached and
pistons in place. Before removing crankshaft, tape threads of
connecting rod bolts to prevent damageto crankshaft. Fasten
connecting rods against sides of engine so theywilE not be in the
way while replacing camshaft bearings.
6-1 6 Englne/eng
1. With camshaft removed,drive out expansion plug at rear of the
rear camshaft bearing. Drive it out from the inside.
~ This procedure is based on removal of the bearing nearest

center of the engine first. With this methoda minimumamountof
turns is necessary to locate the remover in position to remove
next bearing.
2. nnstall nut on puller screw and turn to end of threads on puller

screw using tool J-6098. Index pilot over screw with open end
toward nut on puller screw.
3. Insert remover with shoulder toward number3 bearing, making

sure a sufficient amountof threads are engagedon the puller.
4l. Using two wrenches, hold screw shaft with one wrench while
turning the front nut with the other wrench. After removing
bearing from block, repeat operation for number2 bearingl.
5. Removetool and reassemble tool to remove number 4 bearing

f~rom rear of engine. Assemble remover on driver handle and
removefront and rear bearing.
CamshaftBearing Installation
The number one or front camshaft bearing should be installed

first. This bearing will act as a guide for the tool and center the
number two and three bearing being pulled in place.
L~ 1. Assembleremover and installer tool on driver handl~e and

instalU camshaft front bearing by driving towards center of cylin-
der block.
2. Using Tool Set J-6098, with nut then thrust washerinstalled to

"\!
end of threads, index pilot in camshaft front bearing and install
puller screw through pilot.
~’~ Align oil homesin bearing with oil holes in block before
driving or pulling in place.
,.,.~’ Install nut on puller screwand turn to end threads on puller

screw, index pilot screw, with open end of pilot toward nut.
4l. index number three camshaft bearing on screw, then turn

installer on screw with shoulder toward bearing making sure a
sufficient amountof threads are engagedon the puller.
f
[4~ 5. Turn nut on screw puller to exert pressure on pilot until
bearing is installed. 47327
6. Removeinstaller and repeat steps 4 and 5 for numbertwo and

four bearing.
Engine./eng 6-17
7. install rear bearing in samemanneras numberone bearing.
Caution should be observedwhile installing rear bearing due to
smaller size of oH pressure holes in rear camshaft bearing.
improper alignment of rear camshaftbearing will result in re-
stricted oil pressureto valve train.
8. Coat new camshaft rear plug O.D. with GMNo. 1052080

sealant,or equivalent,andinstall flush to 1/32in. (0,787ram)deep.
Caminstallation
1. Lubricate camshaftjournals with engineoil.
Whenever a newcamshaftis installed, lubricate the cam-

shaft lobes with Molykoteor its equivalent. Also add onecan of
G.M. EngineOil Supplementto crankcaseoil.
2. Install three %e-18x 4 in. bolts in camshaftbolt holes, install

camshaft, being careful not to damagebearings.
3. install camsprocket (makingsure timing marksface outward),

timing chain, rind timing chain cover.
4. install harmonicbalancerandcrankshaftpulley, install circulat-

ing pumpand connect coolant hose.
5. Install valve lifters, pushrods, rocker arms, andintake mani-
fold. install rocker armcovers.
6. Install distributor andset initial timing.

Lubrication System
Descriptionand Operation
The oim pumpconsists of two gears and a pressure relief valve

enclosedin a two-piecehousing, and is driven by the distributor
driveshaft whichin turn is driven by a helix gearon the camshaft.
Thepumpis flange mountedto the cylinder block with two bolts.
Thepumpcover is equippedwith a pressureregulator valve that

regulates oil pressure at approximately 40-60 PSi at 2000RPM.
Thepumpintake is of the fixed screentype. A meshscreenfilters
out small particles of dirt and sludge whichmaybe present.
F~ A baffle incorporated in the intake screen has been de-
signed to eliminate pressureloss dueto suddensurging stops, in
the event that a screen becomesplugged, a steel grommetopens
and bypassesoil to the pump.Oil passesthrough an openingin
the mountingflange to the cylinder block, then into an oil filter
adapter.
Themainoil galleries run the full length of the crankcaseandcut

into the valvelifter guideholesto supplyoil at full pressureto the
lifters. The rocker armsand valves are lubricated by an oil
channelin eachpushrod. Excessoil drains off andreturns to the
oil pan through passagesin the cylinder headand block.
Connecting passagesdrilled in the crankcase permit delivery of
oil at full pressure to all crankshaft and camshaft bearings,
distributor drive gear and shaft, and the timing chain.
Holes drilled in the crankshaft carry oil from the crankshaft

bearings to the connecting rod bearings. Pistons and cylinder
walls are lubricated by oil forced through a small notch iin the
bearing parting surface on the connecting rod, which registers
with the hole in the crankpin once every revolution. Piston pins
are mubricated by splash.
RemoteEngine Oil Filter 28256
L-~ [~ A full flow oil filter (~) is mountedto a bracket attached

to the port exhaust elbow. Twohoses connect it to an oil cooler
and an engine block adaptor (~).
L-~ [~ Oil exits the block through the rear opening © of the
adaptor, and travels through a hoseto the rear oil coomerfitting, it
leaves the front cooler fitting, and travels through a hose that
connects to the filter bracket inner (starboard) opening (~. Return
oil leaves the filter bracket at the outer (port) opening(~), travels
through a hose and re-enters the engine at the forward opening
(~) of the adaptor. 19~A
If hosesare improperUyattached at adaptor or filter brack- ©

et, oil flow will be reversed. Oil pressure wiil drop and engine
damagemay result.
3~ Normally, all engine oil passes from the block through an
OEMfilter adapter ~). if the remote oil filter or lines become
restricted, a spring loaded bypass valve ® opens in the adaptor
and circulates oil back into the block.
L~ Inspect bypass valve spring and vaJve disc (~ for proper
operation or damage,if replacement of bypass valve is neces-
sary, removebolts and adaptor. Clean valve chamberin block and DR2906
replace adaptor.
Removal
1. Removetiming chain cover. See Timing Chain, Cover and Sea|

in this section.
2. Removeoil dipstick and withdraw oil using a suction pump.
3. Removeoil dipstick tube. Removescrews, oil pan and g~sket.
4. Remove
oil dipstick tube fitting from oil pan.
Engine/eng 6-1 g
Installation
1. Thoroughly clean all gasket sealing surfaces.
~] 2. Apply RTVsealer to the front and rear corners of the block.
[~ 3. Attach gasket to block, install rear portion of oil pan seal in

groove in rear main bearing cap.
[~ 4. Install front portion of oil pan seal by pressing the corners

into sealer applied to block.
DR3788
5. install oil pan and tighten screws. See TorqueSpecificationsat
[~ 6. install dipstick tube fitting to pan; leave screw loose.

Orient fitting and attach dipstick tube. Thentighten fitting screw
and flare nut. See TorqueSpecificationsat the end of this section
for the torque figure.
7. Fill crankcase with specified engine oil. See CrankcaseOil in

the General Information Section.
Oil Pump
31576
Removal and Disassembly
1. Removeoil pan.
~] 2. Removepump to rear main bearing cap bolt, and remove

\ ,j J
pump, extension shaft and collar. NOTE:Baffle nuts have to be
loosened.
3. Disconnect pump shaft from extension. Removefour cover

attaching screws, cover, gasket, idler gear and drive gear and
shaft. J~
DR3580
4. Removepressure regulator valve and valve parts.
5. if the pickup screen or pipe need replacing, replace the entire

pump and pickup screen assembly.
6. Washall parts in cleaning solvent and dry using compressed

air.
6-20 Englne/eng
Inspection
Should any of the following conditions be found during inspec-

tion operations, the pumpand pickup screen assembly should be
replaced.
1. Inspect pumpbody for cracks or excessive wear. inspect oil

pump gears for excessive wear or damage.
2. Checkshaft for looseness in the housing. Checkinside of cover

for wear that would permit oil to leak past the ends of gears.
3. Check the oil pickup screen for damageto screen or relief

grommet. Check for oil in the air chamber.
4. Checkpressure regulator valve plunger for fit in cover.
Assemblyand installation
1. Place drive gear’ and shaft in pumpbody. Install idler gear so

that smoothside of gear will be toward the cover.
2. Install a new pump to cover gasket to ensure correct end

clearance of the gears.
3. install cover and attaching screws. Tighten screwsto 80 ill. Ibs.

(9 N-m), and check to see that shaft turns freely.
4. Install regulator valve plunger, spring, retainer and pin.
5. Assemble collar end of extension shaft assembly over pump

driveshaft, aJigning tang of extension shaft with slot in end of
pumpdriveshaft.
6. Assemblepumpand extension shaft to rear main bearing cap,

aligning slot on top end of extension shaft with drive tang on
lower end of distributor shaft. NOTE:Oil pumpshould slide easily
into place, if not, remove and relocate slot or locate other
problem. Install mounting screws and tighten. See Torque $;peci-
fications at the end of this section for the torque figure.
7. Tighten baffle nuts.
8, Install oil pan using newgasket. Connectoil drain tube.
Measuring Camshaft Lobe Lift

1. Removerocker arm covers. Loosen rocker arms and pivot away
from push rods.
[~ 2. Positionindicator with ball socketadapter(J-8520)on pushrod.
Make surepushrod is in the lifter socket.
t
3. Rotatethecrankshaft
slowlyin thedirectionof rotationuntil thelifter is
ontheheelof the camlobe.At this point, thepushrod will bein its lowest
position.
4. Zerothe dial indicator,thenrotatethe crankshaftslowlyuntil the push

rodreaches its highestreadingonthe dial indicator.
,~CAUTION:To preventelectrical sparks,accidentalenginestarting and

fuel spraywheneverthe engineis crankedthe following procedure must
be folbwed.
Gi andGSiModels:removegray andblack connectorsfrom igni=

tioncoil.
[~ GLE,’iodeis:Remove
bothprimarywiresfromthe ignition coil termi-
nals @andtape the ends.
7.4 GLModels
withE.E.M.:Remove th 14-wireconnectorat the ignition
DR5655
module.Remove
electric fuel pumprelay,
5. Compare
the total lift recorded
fromthe dial indicatorwith specifica-
tions.
6. If camshaft
readings
for all Iobesare withinspecifications,remove
dial
indicator assembly.
7. Install valvemechanism
as outlined. Install rockerarmcovers.
RearMainBearingOil seal Replacement

Removal
Pryout rear crankcase

oil seal.
,&,CAUTION:
Becareful not to nick crankcaseseal surfacewhenremov-
ing.
Cleaningand Inspection
[~ 2. Positionthe seal ontotool J-38841

®so seal lip facesthe block.
[~ 3. Positiontool J-38841againstthe crankshaft.Threadthe attaching

screwsinto the tappedholesin the crankshaftandtighten securely.This
will ensurethat the seal ®is installed squarelyoverthe crankshaft.Turn
the handleuntil it bottomsthenremove the toot.
SafetyRelated 6-22
Crankshaft
Description
o
Mainbearings are of the precision insert type and do no1 utilize

shims for adjustment. If clearancesare found to be excessive, a
newbearing, both upperand lower halves, will be required. Bear-
ings are available in standardsize and0.001in., 0.002in., 0.010
in. and0.020in. undersize.
Selective fitting of both rod andmainbearinginserts is necessary

in production in order to obtain dosetolerances. For this reason
you mayfind one-half of a standardinsert with one-half of a 0.001
irl. undersizeinsert whichwill decreasethe clearance0.0005in.
from using a full standardbearing.
Whena production crankshaft cannot be precision fitted by this

method,it is then ground0.009 in. undersize on only those main
journals that cannotbe properlyfitted. All journals will not neces-
sarily be groundundersize.A0.009in. undersizebearingand 0.010
in. undersizebearingmaybe usedfor precision fitting in the same
manneras previously described.
Note If, for any reason, main bearing caps are replaced, shim-
mingmaybe necessary.Laminatedshimsfor each cap arc, = avail-
able for service. Shimrequirementwill be determinedby bearing
clearance.
inspection
in general,(exceptNo. 1 bearing)the lowerhalf of the bearingshows

a greater wearand the mostdistress from fatigue. If uponinspec-
tion the lower half is suitable for use, it can be assumed
that the
upperhalf is also satisfactory. If the lowerhalf showsevidenceof
wear or damage,both upper and lower halves should be replaced.
Neverreplace onehalf without replacingthe other half.
These dimensions should be checked with a micromel:er for

out-of-round, taper or undersize. If the journals exceed0.001in.
out-of-round or taper, the crankshaft should be replacedor recon-
ditioned to an undersizefigure that will enablethe installation of
undersizeprecision type bearings.
Thecrankshaft should also be checkedfor runout. To performthis

operation, supportthe crankshaftat the front andrear mainbearing
journals in "V" blocks, andindicate the runoutof both the rear inter-
mediateandfront intermediatejournals, using a dial indicator. The
runoutlimit of eachof thesejournals is 0.002in. If the runoutex-
ceeds0.002 in., the crankshaft mustbe repaired or replaced.
E.~i,~.~ 6-23
Main Bearing ~earance
To obtain the most accurate results with Plastigage (or its equiva-
®
lent), a wax-like plastic material which will compress evenly
between the bearing and journal surfaces without damaging
either surface, certain precautions should be observed. With the
engine out of the boat and upside down, the crankshaft will rest
on the upper bearings and the total clearance can be measured
between the lower bearing and journal.
To ensure the proper seating of the crankshaft, all bearing

cap bolts should be at their specified torque. In addition, prepara- 47397
tory to checking fit of bearings, the surface of the crankshaft
journal and bearing should be wiped clean of oil.
1. With the oil pan and oil pumpremoved, and starting ,with the
rear main bearing, remove bearing cap. NOTE: Wipe oil from
journal and bearing cap before applying Plastigage.
E~] 2. Place a piece of gauging plastic ~ the fuin width of the

bearing (parallel to the crankshaft) on the journal.
Do not rotate the crankshaft while the gauging plastic is

3. InstalJ the bearing cap and evenly torque the retaining bolts to
specifications.

found adhering to either the bearing shell or journal.
47407
[~ 5. On the edge of gauging plastic envelope there is a
graduated scale which is measured in thousandths of an inch.
Without removing the gauging plastic, measure its compressed
width (at the widest point) with the graduations on the gauging
plastic envelope.

round journal (0.001 in. maximum),be sure to fit to the maximum
diameter of the journal, if the bearing is fitted to the minimum
diameter and the journal is out-of-round 0.001 in., interference
between the bearing and journal will result in rapid bearing
failure, if the flattened gauging plastic tapers toward the middle
or ends, there is a difference in clearance indicating taper, low
spot or other irregularity of the bearing or journal. Be sure to
measurethe journal with a micrometer if the flattened gauging
plastic indicates morethan 0.001 in. difference.
6. If the bearing clearance is within specifications, the bearing

insert is satisfactory, if the clearanceis not within specifications,
replace the insert. Always replace both upper and lower insert as
a unit.
E~ If a new bearing cap is being installed and dearance is less
~han0.001 in., inspect for burrs or nicks; if none are founcl then
install shims as required.
’7. A standard size,, 0.001 in. or 0.002 in. undersize bearing may
produce the proper clearance. If not, it will be necessary to
regrind the crankshaft journal for use with the next undersize
bearing.
8. Proceed to the next bearing. After all bearings have been

drag.
E3~ 9. Measure crankshaft end play (see Specifications)
forcing the crankshaft to the extreme front position. Measureat
the front end of the rear main bearing with a feeler gauge.
10. Install a newrear main bearing oil seal in the cylinder block 47417
and main bearing cap.
Main Bearing Replacement
E4~ 1. install a main bearing removing and installing tool J-8080

~) in oil hole in crankshaft journal. NOTE:if such a tool is not
available, a cotter pin maybe bent as required to do the job.
2. Rotate the crankshaft clockwise as viewed from the front of

engine. This will roll upper bearing out of bJock.
3. Oil new selected size upper bearing and insert plain (unnotc-
bed) end between crankshaft and indented or notched side of
block. Rotate the bearing into pRace,and removetool from oil’ hole
in crankshaft journal
4. Oil new lower bearing and install in bearing cap. Install main
bearing cap with arrows pointing toward front of engine. Torque DR2916
main bearing cap bolts to specifications.
(~nnecting Rod Bearing Replacement
Connecting rod bearings are of the precision insert type and do

not utiJize shims for adjustment. DO NOTFILE RODSOR ROD
C~PS.If clearances are found to be excessive a new bearing will
be required. Bearings are available in standard size and 0.001 in.
undersize for use with standard size crankshafts.
1. With oil pan and oil pumpremoved, removethe connecting rod

cap and bearing.
Engine/eng 6-25
2. Wipethe bearings and crankpin dean of oil. Inspect the bearing
for evidence of wear or damage.
3. Measurethe crankpin for out-of-round or taper with a microme-

ter. Rf not within specifications, replace or recondition the crank-
shaft. If within specifications and a newbearing is to be installed,
measure the maximumdiameter of the crankpin to determine
new bearing size required.
4. If within specifications, measurenew or used bearing clear-

ances with Plastigage or its equivalent.
if a bearing is being fitted to an out-of-round crankpin, be

sure to fit to the maximum diameter of the crankpin, if the bearing
is fitted to the minimumdiameter and the crankpin is out-of-
round 0.001 in., interference between the bearing and crankpin
will result in rapid bearing failure.
a. Place a piece of gauging plastic the full width of the

crankpin parallel to the crankshaft. (Note: Surfaces must
be free from oil.)
b. Install the bearing in the connecting rod and cap.
c. install the bearing cap and evenly tighten nuts to specifi-

cations.
Do not turn the crankshaft with the gauging plastic

insta|led.
d. Removethe bearing cap and using the scale on the

gauging plastic envelope, measurethe gauging plastic
width at the widest point.
5. If the clearance exceedsspecifications select a new, correct size

bearing and remeasure the clearance.
6. Coat the bearing surface with oil, install the rod cap and tighten
nuts to specifications.
7. Whenall connecting rod bearings have been installed tap each

rod lightly (parallel to the crankpin) to makesure they have
clearance.
[~ 8. Measureall connecting rod side clearances (see Specifica-

tions at end of this section), between connecting rod caps.
Piston, Ring and Connecting Rod

4742.7
Piston and Rod Removal
1. Removeoil pan, oil pumpand cylinder head. Turn crankshaft

until piston is at bottom of stroke. Place a cloth on top of piston to
collect cuttings.
6-26 Engins/eng
2. Use a ridge reamer to removeany ridge and/or deposit.,~ from
the upper end of the cylinder bore. After ridge and/or deposits are
removed, turn crankshaft until piston is at top of stroke and
removecloth and cuttings.
3. inspect connecting rods and connecting rod caps for cylinder

identification. If necessary mark them.
E2~ 4. Removeconnecting rod cap and instala tool J-5239 on

studs. Push connecting rod and piston assembly out of top of
cylinder block.

disconnect some of the connecting rod and piston assemblies
and push them out of the cylinder.
Piston and Rod Disassembly J 5239--~
1. Removeconnecting rod bearings from connecting rods and

caps.
If connecting rod bearings are being reused, place them in

a rack so they maybe reinstalled in their original rod and cap.
DR3792
2. Removepiston rings by expanding them and sliding them off
the pistons. Ring expandertools are available from local automo-
tive stores.
3~ 3. Using tools J-24086-20 (~) and J-24086-8 (~), place connect-
ing rod and piston assembly in an arbor press with piston on
support, then using remover, press piston pin out of connecting
rod and piston.
4. Removeassembly from arbor press and remove tools, piston

pin, connecting rod and piston.
5. Clean varnish from piston skirts and pins with a cleaning

solvent. DO NOTWIREBRUSHTHE PISTONSKIRT. Clean the ring
grooves with a groove cleaner, and makesure oil ring holes and
SlOtSare clean.
6 Inspect the piston for cracked ring lands, skirts or pin bosses;
wavy, worn ring lands; scuffed or damagedskirts; or eroded
areas at top of the piston. Replace pistons that are damagedor
7. Check fit of used piston pins. Use a dial bore gauge or

telescoping gauge for the bore and a micrometer for the pin. Wear
limit for piston to pin clearance is 0.001 in. maximum.Replace 94136
piston and pin assembly if wear is excessive.
Englne/en9 6-27
either pin boss whencoated with light engine oil and at 60° F.
Higher or lower temperatures will cause false indications.
--®
Piston pins are matched fit to the piston and are not available
knock or tapping until after prolonged use, and in such cases a
new piston and pin assembly should be installed.
1. Lubricate piston pin holes in piston and connecting rod to

[~ 2. Use J-24086-20, J-24086-9 and guide tools. Place connect-

ing rod in piston and hold in place with piston pin guide (~) and
piston pin ®. Place assembByon fixture and support assembly ©.
3. Using piston pin installer J-24086-9 (~, press the piston

pin into the piston and connecting rod.
94137
Thepiston pin installer is a variable insertion length tool.
The insertion length is varied by rotating the hub on the shaft
muchlike adjusting a micrometer. An alphanumeric scale is used
to determine the desired length for a given piston pin assembly.
[~ After installer hub bottoms on support assembly, do not
exceed 5000 PSi pressure, as this could cause structural damage
to the tool.
4. Removepiston and connecting rod assembly from tool and

check piston for freedom of movementon piston pin.
Piston Rings
Piston rings are furnished in various sizes. Refer to your parts

catalog for sizes available.
Oil control rings consist of two segments(rails) and a spacer.
Compressionrings are the deep section twist type, 3/~2 in. wide.
This type compression ring takes its name, twist type, from its
installed position which is cocked or twisted, it assumesand
section.
6-28 Englne/eng
I~ All compression rings are marked with the letters "GM"
,cast in the upper side of the ring. Wheninstalling compression
piston.
1. SeJect rings comparablein size to the piston being used.
it is important that each ring be fitted to its individual

cylinder for proper gap spacing, and to its individual piston and
groove for proper groove clearance.
2. Slip the compressionring in the cylinder bore; then, using the

head of a piston, press the ring downinto the cylinder bore about
1/4 in. (6,5 ram).
the cylinder walls.
3. Checkthe space or gap betweenthe ends of the ring with a

feeler gauge. If the gap between the ends of the ring is below
specifications, removethe ring and try another for fit. Fit eachring
separately to the cylinder in which it is going to be used.
4. New pistons, rings and cylinder bores wear considerably 860048

greater than 1/32 in.
5. Carefulmyremoveall particles of carbon from the ring groove in

the piston and inspect the groovescarefully for burrs or niclcs that
might cause the rings to hang up.
4~ 6. Slip the outer surface of the top and second compression
ring into their respective piston ring groove, and roll the ring
entirely around the groove to makesure the ring is free and does
not bind in the groove at any point, if binding occurs, the cause
should be determined and removedby carefully dressing with a 10755
fine cut fileo However,if the binding is causedby a distorted ring,

install a newring. 0
Piston Ring installation
E~ 1. Install the oil ring spacer in the oil ring groove, and insert
antirotation tang in oil hole. Homdspacer ends butted, and install
steel rail on top side of spacer. Position gap(~) at least one inch
left of spacer gap (~ then install second rail on lower side of
spacer. Position gap @at least one inch to right of spacer gap (~.
2. Flex the oil ring assemblyin its groove to makesure ring is free DR2908
and doesnot bind in the groove at any point. If binding occurs, the
cause should be determined and removed by carefully dressing
with a fine cut fiae. However, if the binding is caused by a
3. install second compression ring and mocategap (~, then

top compression ring and locate gap O.
E~/..= 6-29
[~ 4. Proper clearance of the piston ring in its piston ring groove
is very important in maintaining engine performance and in
preventing excessive oil consumption. Therefore, when fitting
new rings, the clearance between the top and bottom surfaces of
F~ 5. The upper compression ring should be fitted so that the
clearancefalls within the Specifications at the end of this section.
For clearance of lower compression ring, also see Specifications
at the end of this section.
6. Assemblethe rings to the pistons as they are fitted, and makea 860050
procedure given above. II , 4 "
Piston and RodInstallation ~~l Ill
oil.
2. With bearing caps removed, install tool J-5239 on bearing cap

bolts.
[~ Check position of ring end gaps. They must be aligned
FRT.
DR3783
with each other as described previously. See Piston Ring Installa-
tion.
3. install eachpiston in its respective bore, using tool 3-5239

on each assembly. The dimple ~) in the piston faces forward and
the oil hole on the connecting rod should be to the center of the
cylinder block. Guide the connecting rod into place on the
crankshaft journals with the long detail of tool J-5239.
[~ 4. Use tool 3-8037 (~) to compressthe piston rings.
5. Install bearing caps and check the bearing clearance as de-

scribed previously. 47437
Cylinder Block
inspection
1. Checkthe cylinder block for cracks in the cylinder wails, water

E~ 2. Checkthe cylinder walls for taper, out-of-round or exces-

sive ridge at top of ring travel. This should be done with a dial
indicator 3-8087. Set the gauge so that the thrust pin must be
forced in about 1/4 in. (6,5 ram) to enter gaugein cylinder bore.
Center gauge in cylinder, and turn dial to "0.’" Carefully work
gauge up and down cylinder to determine the out-of-round
condition, if cylinders were found to have more than 0.002 in.
out-of-round, boring will be necessary.
860¢53
6-30 En~i~/,~
Cv|inder Conditioning
"The performance of the following operations is contingent upon

ff the cylinder block inspection indicated that the block was

suitable for continued use except for out-of-round or tapered
cylinders, they can be conditioned by honing or boring and
honing.
If the cylinders were found to have less than 0.005 in. (0,13 mm)
the high limit standard size piston. A cylinder bore of less than
0.005 in. (0,13 mm)wear or taper maynot entirely clean up, when
fitted to a high limit piston, if it is desired to entirely clean up the
bore in these cases, it will be necessaryto rebore for an oversize
piston. If morethan 0.005 in. (0,13 mm)taper or wearexists, they
should be bored and honed to the smallest oversize th;~t will
permit complete resurfacing of all cylinders=
Cylinder Boring
11. Before using any type boring bar, the top of the cylinder block
should be filed off to removeany dirt or burrs. This i,,~ very
important. Otherwise, the boring bar maybe tilted which ,would
crankshaft.
2. Place the hone into a cylinder bore, and expandthe stones until
the honecan just be turned by hand. Connecta 1~ in. electriic drill
to the hone, and drive hone at drill speed while moving hone up
and downentire length of cylinder until hone begins to run free.
During this operation, a liberal amount of kerosene should be
used as a cutting fluid to keep the stones of the hone clean. Move
hone slowly up and down with rough stones, but move hone up
and downrapidly enoughwith the fine stones to produce ~3 final
bore finish of very fine surface scratches in a crosshatch pattern
of approximately 45° to 65° included angle. The marks should be
clean but not sharp, and free from embeddedparticles or torn or
folded metal.
3. Expandthe stones against the cylinder bore, and repe,at the


should be thoroughly cleaned and the piston selected for the
individual cylinder checkedfor correct fit.
5. Thoroughlyclean the cylinder bores with hot water and soap.
Scrubwell with a stiff bristle brushandrinse thoroughlywith hot
water, it is extremelyessential that a goodcleaning operationbe
performed.If any of the abrasivematerial is allowedto remainin
the cylinder bores, it will rapidly wearthe newrings andcylinder
bores. In addition, the bearingswill be lubricated by the contami-
nated oil. Thebores should be swabbed several times with light
engine oil and a clean cloth, and then wiped with a clean dry
cloth. Cylinders should not be cleanedwith keroseneor gasoline.
Clean the remainderof the cylinder block to removethe excess
material spreadduring the honing operation.
PistonSelection
1. CheckUSED
piston to cylinder bore clearanceas follows:
a. Measurethe "Cylinder Bore Diameter" with a telescope

gauge2 1,~ in. (64 mm)from top of cylinder bore.
b. Measure the "Piston Diameter"(at skirt across centerline

of piston pin).
c. Subtract piston diameterfrom cylinder bore diameterto

determine "Piston to Bore Clearance."
d. Calculate piston to bore clearance and determine if
piston to bore clearanceis in the acceptablerange.
2. If usedpiston is not acceptable,checkif a newpiston can be

selectedto fit cylinder bore within the acceptablerange.
3. if cylinder bore must be reconditioned, measurenewpiston
diameter(across centerline of piston pin), then honecylinder bore
to correct clearance(preferable range).
4. Markthe piston to identify the cylinder for whichit wasfitted.
Handlethe pistons with care, and do not attempt to force

themthrough the cylinder until the cylinder has beenbored to
correct size as this type piston can be distorted throughcareless
handling.
Circulating Pump
[~ The Volvo Penta circulating pumpis manufactured spe-
cially for marineuse. it is serviced only as an assembly.Do not
replace with an automotivecirculating pump.
inspection
1. Removealternator and powersteering belts. Graspcirculating

pumppulley and checkendand side play. Turn pulley to checkfor
drag.
2. Lookfor water leaking from indicator hole beneathpumpshaft

behindpulley. Replacepumpif play, drag, or leakageare evident.
6-32
Removal
andinstallation
11. Drain water from block and disconnect water hose from
circulating pump. Removepulley. Removecirculating pump
bolts, pumpand gaskets.
2. Use newpumpto block gaskets and sealer, install newpump

assembJy on cylinder block andtighten bolts as specified, install
pulley. Install alternator andpowersteering belts, then adjust
tension.
3. Connecthoseto circulating pump.Lakeor tank test unit and 11981

checkfor leaks.
Front Engine MountReplacement
Removal
[1--] 1. Remove
two lag screws (~) and washersfrom mounts.
2. Lift enginewith 1500lb. (680 kg) minimum

capacityhoist
to allow removalof front mountand bracket.
r2--~ 3. Remove
three mountscrews and lock washers~). 11980
3~ ~ Prior to disassembly of front mount assembly, mea-

sure distance between large washer and flat on upper mount
bracket.
Disassembly
4~ 1. Removethree Iocknuts © and engine mount bracket ~)
from mountbolt while holding bolt securewith socket (~).
~-J 2. Removetwo washers ® and engine mount bolt @from
mount. _T]. 11979
Reassembly
E6~1. Place small washer® on mountbolt and insert bolt up
through mount, install large washerand secure with nut (~).
Tightento 60-75ft. Ibs. (81-102N-m).
~ 2. Install upper inner nut and place engine mountbracket (~)
on engine mount boJt. NOTE:Measuredistance between large
washerand flat on upper mountbracket. Distance must be the
sameas that prior to disassembly.
11978
E~,9~,~,’~ ~ Safety Related 6-33 11983

3. mnstail lock washer and top nut. Tighten nut to 50-70 ft. ibs.
(68-95 N.m).
installation
1. Spray the engine mount screws threads with Loctite primer or

equivalent and allow to air dry. Apply Loctite or equivalent to the
screws. Attach engine mount assembly to engine with three
screws and washers. Tighten to 32-40 ft. Ibs. (43-54 N.m}.
2. Install lag screws and tighten securely.

2953
Height Adjustment
~] 1. To changeengine height, tighten or loosen nuts (~) and

as required.
2. Lift engine with 1500 |b.(680 kg) minimum

capacity hoist.
Position engine at desired height.
EEl 3. After setting mount position, turn upper inner nut (~)
against underside of engine bracket and hold nut with a wrench.
Tighten top nut (~) to 100-120ft. Ibs. (136-163 N-m).
28262
Removal
Drain water from respective exhaust manifold.
1. Loosen two clamps securing upper hose to elbow.
2. Port Elbow - Removetwo thru-bolts, lock washers, and

washerssecuring remote oil filter bracket. Movefilter aside.
Z~ Safety Related 6-34 EngJne/eng

[3~ 3. Starboard Elbow- Remove two thru-bolts (~), lock wash-
ers, and washersattaching circuit breaker bracket. Set bracket
assemblyaside.
E~ 4. Lubricate inside of exhaust hose with a soapy water
solution, then removeremaining elbow bolts. Tapelbow with a
soft hammer to free it, then twist it out of the hose. Remove
and
discard the manifold gasket.
installation
5L~ 1. Apply Gasket Sealing Compound to both sides of a new 3 19670
gasket ®, and place it on the manifold. Lubricate inside of
exhausthosewith a soapywater solution to easeelbowinstalla-
tion.
2. Twist elbowinto hoseandposition it on the gasket. Install the
outer rear thru-bolt, washerandlock washer,andturn it in finger
tight.
[~ 3. Port Elbow- Position remoteoil filter at front of elbow.

Install four thru-bolts, washersandlock washersfinger tig~ht.
[3~ 4. Starboard Elbow- Position circuit breaker assemblyat
28265
front of elbow.Install two thru-bolts ~), washersandlock washers
finger tight. Install remainingthru-bolts, washersandlock wash-
ers finger tight.
5. Tightenall elbowthru-bolts to 12-18ft. Ibs. (16-24N-m).

L~ 6. Properly position the two exhaust hoseclampsand tighten
them securely.
26266
Eng|neleng ~ Safety Related 6-35

Replacement
Removal
1. Loosen eight clamps that attach the upper and lower exhaust
hoses, and slide clamps down onto exhaust Y-pipe.
[~ 2. Lubricate inside of lower hose with a soapy water solu-

tion, and push lower hose down onto exhaust Y-pipe.
[~ 3. Twist intermediate pipe out of upper hose. Lubricate

inside of upper hose with a soapy water solution if necessary to
ease removal
4. Slide upper hose off high-rise elbow. Slide lower hose off
exhaust Y-pipe.
Installation
1. Lubricate inside diameter of 3.5 in. (8,89 cm) i.D. lower hose
with a soapy water solution. Slide it all the way onto the exhaust
Y-pipe.
28264
~] 2. Onthe inside of the 4 in. (10,16 cm) IoD. upper hose, there
is a circular rib 1.5 in. (3,81 cm) from one end. The ribbed end
the hose must face the intermediate pipe (rearward) when it’s
installed. Slide hose onto high-rise elbow until it seats. NOTE:if
hose is not properly positioned, it will not completely engagethe
high-rise elbow or allow secure attachment.
3. With a twisting motion, insert intermediate pipe all the

way into the upper hose. Slide the lower hose up until it’s halfway
onto the intermediate pipe.
Z~ 4. Slide four No. 68 clamps up onto the upper hose. Slide four
16O41
No. 64 clamps up onto lower hose. Position clamps in their
proper channels and tighten them securely.
Safety Related 6-36 Eng~ne/eng

EngineSpecifications -- - -
7.4 and 8.2 GL, Gi, and GSi
Type - No. of Cylinder ................................. 90° - V-8

Valve Arrangement ............................ Ow.=rheadValves
Bore and Stroke:

7.4 models ................. 4.250 x 4.000 in. (107,95 x 101,6 mm)
8.2 models ................. 4.468 x 4.000 in. (113,48 x 101,6 mm)
Piston Displacement
7.4 models ......................... 454 Cubic Inches (7.4 Liters)
8.2 models ......................... 502 Cubic Inches (8.2 Liters)
Cylinder Numbers- Front to Rear

Starboard ............................................. 2-4-6-8
Port .................................................. 1-3-5-7
Firing Order .................................... 1-8-4-3-6-5-7-2
CompressionRatio
7.4 GL .................................................. 8.0:1
7.4 Gi, GSi .............................................. 8.6:1
8.2 GL .................................................. 8.8:1
Water Temperature Control .......................... Thermostat
Thermostat Opens @.............................. 160°F (71°C)
Fuji Throttle Operating Range

7.4 GL, Gi .................................... 4200 - 4600 RPM
7.4 GSi ....................................... 4800 - 5200 RPM
8.2 GI ....................................... 4400 - 4800 RPM
Pistons:
Production Clearance
7.4 Models ............... 0.003 - 0.004 in. (0,0762 - 0,1016 mm)
8.2 Models ................ 0.004 - 0.005 in. (0,1016 - 0,1270 mm}
Service Limit .............................. 0.005 in. (0,127 mm)
Piston Rings:
Top Groove Clearance .... 0.0012 - 0.0029 in. (0,0304 - 0,0736 mm)
Second Groove Clearance 0.0012-0.0029in. (0,0304-0,0736mm)
Third Ring Groove Clearance 0.005- 0.0065 in. (0,127- 0,1651 mm)
Service Limit ........................... +0.001 in. (+0,0254 mm)
Top Ring Gap ................. 0.010 - 0.018 in. (0,254 - 0,457 mm)
Second Ring Gap ............. 0.016 - 0.024 in. (0,406 - 0,609 ram)
Third Ring Gap ............... 0.010 - 0.030 in. (0,254 - 0,762 mm)
Service Limit ............................. +0.010in. (0,254 ram)
Piston Pins:
Diameter ................ 0.9895 - 0.9897 in. (2,5133 - 2,5138 mm)

Clearance ............... 0.0002 - 0.0007 in. (0,0050 - 0,0177 mm)
Service Limit .............................. 0.001 in (0,0254 ram)
RodFit, interference fit ... 0.0031 -0.0021 in. (0,0787-0,0533 mm)
Connecting Rod:
Bearing Clearance, New0.0011 - 0.0029 in. (0.0279 - 0.07386 mm)

Bearing Clearance, Service Limit ............ 0.003 in. (0,0782 ram)
Side Clearance ........... 0.0013 - 0.023 in. (0,0330 - 0,5842 ram)
Crankshaft:
Thrust ..................... 0.006 - 0.010 in.( 0,1524 - 0,254 mm)
Main Journal
Main Bearing Clearance, New

No.l, 2, 3, 4 ............. 0.0017 - 0.0030 in. (0,0432 - 0,0762 mm)
No. 5 ................... 0.0025 - 0.0040 in. (0,0835 - 0,0965 ram)

No. 1,2, 3, 4 ............ 0.0010 - 0.0030 in. (0,0254 - 0,0762 mm)
No. 5 ................... 0.0025 - 0.0040 in. (0,0635 - 0,1016 mm)
Crankpin Diameter
7.4 GL ................... 2.199 - 2.1996 in. (55,854 -55,8698 mm)
8.2 GL ..................................... 2.20 in. (55.88 mm)
Taper and Out-of-Round, New............. 0.0005 in. (0,0127 mm)
Taper and Out-of-Round, Service Limit ....... 0.001 in. (0,0254 mm)
Camshaft:
CamshaftBearing Journal E:tl.9482 - 1.9492 in. (49,484 - 49,509 mm)
7.4 Models
Lift, intake .............. 0.2343 + 0.002 in. (5,9512 +_ 0,0508 mm)
Lift, Exhaust............. 0.2530 + 0.002 in. (6,4262 + 0,0508 mm)
8.2 Models
Lift, Intake and Exhaust.... 0.510+0.002in. 12,954_+0,0508mm)
8-38 E~ine/eng
Valve Systems:
Lifter Type .......................................... Hydraulic
Rocker Arm Ratio

7.4 GL, Gi ............................................... 1.7:1
8.2 GL, 7.4 GSi .......................................... 1.7:1
Valve Adjustment ............................ zero lash + one turn
Valve Angle .............................................. °45
Seat Angle ............................................... °46
Valve Seat Run-out .............. +0.002 in (0.0508 ram) Maximum
Valve Stem Clearance

Intake, New............. 0.0010 - 0.0027 in. (0.0254 - 0,0270 ram)
Exhaust, New............ 0.0012 - 0.0,029 in. (0,0304 - 0,0736ram)
Intake, Service Limit ...................... +0.001 in. (0,0254 mm)
Exhaust, Service Limit .................... +0.002 in (0,0508 ram)
Valve Seat Width, Intake ....... 1/32 to 1/16 in. (0,794 to 1,587 ram)
Valve Seat Width, Exhaust ..... 1/16 to 3/32 in. (1,587 to 2,381 ram)
Valve Spring Length ......................... 2.15 in. (54,41 ram)
Valve Spring Installed Height, Installed ...... 1 51/64 in (45,641 mm)
Valve Spring Pressure

Ibs. @in. (kg @mm)compressed... 74-86@1.80in. (33,5-39@45.72)
Ibs.@ in. (kg@ mm) compressed 195-215@1.40in.(88.4-97.5@35.56)
Installed Height ............................. _+ 1/32 in. (0,794 mm)
Valve Spring Fit In Damper......... 0.042 - 0.094 in. (1,06 - 2,38 mm)
EngineLubrication:
Type Oil Pump............................................ Gear
Normal Oil Pressure, WarmEngine ..... 10 psi (70,3 kPa) @500 RPM
40-60 psi (281-422 kPa) @2000 RPM
Crankcase Capacity
7.4, 8.2 GL ............. 6 qts (5,67 liters); 7 qts (6,62 liters) w/filter
7.4 Gi, GSi ............. 8 qts (7,57 liters); 9 qts (8,51 liters) w/filter
C)il Grade Recommended

32° F (0 ° C) and above ................................. SAE 30
0° F (-18 ° C) to 32° F (0° C) ........................ SAE 20W-20
-0° F (-18 ° C) and below .............................. SAE 10W
Werecommend Volvo PentaDuraPIusTM Synthetic MotorOil, which is specially
formulated for heavyduty marine use, and ideal for Volvo PentaEngines.tt
providesbetter anti-wearqualities, especiallyduring long high speedoperation.
In addition, it neutralizesacidscommonto all internal combustionengines,offers
superiorcorrosionprotection, andis formulatedto offer better resistanceto oxi-
dation andhigh temperaturesludge formation.
Fuel Recommendation............ See General Information Section

TorqueSpecifications
Thefollowingspecificationsare for screwsizes not otherwiseshown
in tables:
ScrewSize Ft. Lb. In. Lb. Nm
No. 6 7 - 10 0,8- t
No. 10 2- 3 25- 35 3- 4
No. 12 3- 4 35- 45 4- 5
1/4 5- 7 60- 80 7- 9
5/16 10- 12 120- 140 14- 16
3/8 18 - 20 220- 240 24 - 27
Usea reliable torquewrenchto tighten the parts listed to preventstraining or distorting the parts or possiblydamaging
the
threads.Thesespecifications are for cleanthreadsonly. dirty threadsproducefriction whichpreventsaccuratemeasure-
mentof torque. It is importantthat thesetorque specifications be strictly observed.Overtighteningto anyextent may
damage threads or equipment,and mayrequire replacementof fasteners and damaged parts=
ITEM Ft. Lb, in. Lb. Nm
CamshaftSprocket 20 27
7.4 GL,Gi 20 27
8.2 GL 25 34
Circulating Pump 30 40
Distributor Clamp 25 34
DipstickTubeFitting 15-18 20-24
Bellhousing 32-40 43-54
BellhousingCover 60-84 7-9
EngineMountto Block 32-40 43-54
Oil Pan 200 22
Oil Panto Front Cover 70 7,9
Oil PumpCover 80 9
PowerSteering PumpBracket 28-30 35-41
ThermostatHousing 12-16 16-22
Timing ChainCover
7.4 GL,Gi 106 12
8.2 GL 120 13,6
Water Pump
7.4 GL,Gi 30 40
8.2 GL 35 47
6-40 Engine/eng
Torque Specifications (cont.) .....
iTEM Ft, Lb. in. Lb. Nm
ConnectingRod
7.4 GL,Gi 48 65
8.2 GL 73 99
ExhaustManifold 20-26 27-35
FlameArrestor 25-35 2,8-4,0
FlameArrestor Cover 30-35 3,4-4,0
Flare-Dipstick Tube 15-18 20-24
FlywheelBellhousing 3R-40 43-54
Flywheeland Coupler 40-45 54-61
FrontMount(top) 100-120 136-163
Rocker Arm Cover 115 13
Cylinder Head
Step1 35 47
Step 2 65 88
Step 3 85 115
ExhaustManifold 24.-28 33-38
Flywheelto Crankshaft 70 95
HarmonicBalancer
7.4 GL,Gi 85 115
8.2 GL 90 112
ExhaustRiser 12-18 16-24
Intake Manifold
7.4 GLGi (lower manifoldonly on Gi models) 30 40
8.2 GL 35 47
MainBearingCap(All)
7.4 GL,Gi 100 135
8.2 GL 110 149
Oil Pump
7.4 GL,Gi 65 90
8.2 GL 70 95
Remote Oil Filter to Block 20-25 27-34
Vibration Damper (use Loctite@242on bolt) ;!4 33
Rocker Arm 40 54
PowerSteering Pump 13-15 18-20

Rocker ArmCover 60-90 7-10
Oil Filter Oneturn after gasket.contact
SparkPlugs ;!2 30
E.oi.~/..~ 6-41
NOTES
Section 7
Steering System
Table of Contents
Mechanical (Non-power) Steering PowerSteering System(cont.)

System - SX ............................ 7-2 External Leakage ...................... 7-18
Cable Installation - SX................... 7-2 Feedback To Helm ...................... 7-21
Cable Removal - SX ..................... 7-2 Hoses ................................ 7-14
Lubrication - SX ........................ 7-3 Hydraulic Fluid .......................... 7-8
Sealants, Lubricants and Adhesives ....... 7-1 Lubrication ............................ 7-13
Steering Tube Replacement- SX .......... 7-3 PumpInstallation ........................ 7-8
Trim Tab Adjustment .................... 7-15 PumpLeakage ......................... 7-19
PumpOperation ......................... 7-7
Power Steering System ..................... 7-4 PumpPressure Test .................... 7-19
Belt Adjustment ........................ 7-10 PumpRemoval .......................... 7-8
Cable Installation ....................... 7-13 Purging Air From Steering System......... 7-9
Cable Installation Problems.............. 7-20 Seala.nts, Lubricants, and Adhesives....... 7-1
Checking Fluid Level .................... 7-9 Special Tools ........................... 7-1
Cylinder Installation .................... 7-12 Specifications - TorQ, ue ................. 7-21
Cylinder Removal ...................... 7-11 Steering Without PowerAssist ............ 7-6
Cylinder Servicing ...................... 7-12 System Diagnosis ...................... 7-14
Description ............................. 7-4 System Operation ....................... 7-5
Diagnosis Chart ........................ 7-16
Special Tools Required: Materials Required:
Crowfoot Wrench(steering cable anchor nut) Volvo Penta Grease

P/N 9995443-0 8.2 GL PumpPulley Remover Volvo Pentapowertrim/tilt & steering fluid
P/N 9995444-8 8.2 GI_ PumpPulley Installer or GMPower Steering Fluid
P/N 3854367-4 Volvo Penta Hydraulic Cylinder Rod Oexron, or Dexron II
Holder
Safety Warnings
Beforeworkingon anypart of the engine,readthe sectioncalled Safetyat the
endof this manual.
Unlessinstructed otherwise, alwaysdisconnectthe battery cables from the
battery beforeworkingon electrical systemto preventpossiblesparksor arc-
ing in the enginecompartment.
Beforestarting engineafter repair or maintenance

procedures,alwsl.ys make
sure enginecompartmentis free of fuel vaporsto preventpossible fire and
explosion.
When workingon an enginethat is runningor being cranked,useextremecare

to avoidgetting hands,fingers or clothingcaughtin the alternator, powersteer-
ing pump,supplypump,andcirculating pumpbelts, pulleys andother moving
parts.
®
C02740 18638 18640
Mechanical (Nonpower) Steering System SX

Models
Description
[~ The mechanical steering system consists of a helm assem-

bly ~), the steering cable ~), and attaching hardware © that
connect the steering system to the inner transom shield and
steering arm.
Steering Cable Removal 6825
The steering cable is serviced as an assembly.

J~ r-~ 1. To remove the steering cable, remove the cotter pin
@and steering arm pin (~ securing the cable ram to the steering
arm ®. Removeboth steering arm bushings (~.
2. Turn the heJmto the port full lock position.

[~] 3. Loosen the cable anchor nut (j~, and removethe cable.
Steering Cable installation 31837
Steering tube position in the anchor block is preset at the

factory for proper centering of the steering system. Do not loosen
the jam nut or changethe position of the steering tube.
[~ ~ 1. Turn the steering wheel to fully extend the steering

cable ram to its maximumextension. Lubricate the full length of
the steering cable ram with Volvo Penta Grease.
2. Install the steering cable ram through the steering tube.
3. While holding the steering cable in the steering tube, thread the
2921
steering cable anchor nut onto the steering tube until the steering
cable anchor nut bottoms on the end of the steering tube.
~ 4. Attach a crowfoot wrench O at a 90° angle to the

torque wrench. Tighten the steering cable anchornut to a torque
of 120 in. Ibs. {14 N-m).
Z~ Safety Related 7-2 3

EnQ~
~-~ ~] 5. Insert bushings (~) into steering arm. Install the
steering arm pin ® through the top hole in the steering arm ®
and through the hole of the steering cable ram.
[2~ Z~ 6. Install the cotter pin @through the steering arm pin
and secure by spreading the ends of the cotter pin.
7. Turn the steering wheel to fully extend and retract the

steering cable ram (~. The steering arm should movefrom stop to
stop as the steering ram moves from fully retracted to fully
extended. Steering arm must not contact inside of transom cutout
in either direction. Check for equal clearance of steering arm. 3253
Center the steering wheel and check centering of steering arm.
Readjust as necessary.
®
Manual Steering SystemLubrication
[8~ Z~ Lubricate the steering ram with Volvo Penta Grease
every 60 days.
Steering TubeReplacement- SX Models

1. Loosen the jam. nut and screw the steering tube out of the
anchor block. Removethe jam nut from the steering tube. DR172,
2. Screwthe jam nut (~) all the wayonto a newsteering tube.
[-~ 3. Measure :3-1A in. (8,26 cm) (D in from the end of

steering tube. Clean the following 1-1/4 in. (3,18 cm) of thread
®
with Loctite primer or equivalent and allow to air dry. Apply
Loctite or equivalent to the 1-1/4 in. (3,18 cm) thread area ~). m
[~ 4. Screw the anchor block onto the steering tube until the
block is 3-%2 in. (8,02 cm) (~ from the end. This dimension
positions the steering tube for accurate centering of the steering
system.
DR1727
5. Screw the jam nut up against the anchor block and tighten to a
torque of 35-40 ft. Ibs. (47-54 N-m). Do not disturb the ~lnchor
block position while tightening the nut.
[~ ~ 6. If the anchor block was removed from the tran-

som plate, apply a small amount of Volvo Penta Grease to both
bushings, install the block with the original screws. Tighten both
t:o a torque of 40-45 ft. ibs. (54-61 N-m). Securescrews with two
cotter pins.
[~ Filling the bushing pockets with grease can cause the

screws to hydraulically lock and break transom plate when 80~2
tighten.
80~1
®
©
@
®
_____®
@
Power Steering System e The oim cooler (~) is a heat exchangerthat uses
engine cooling water to keep the hydraulic fluid
Description cool.
The power steering system consists of a mechan- ¯ A high pressure hydraulic hose @carries fluid
ical cable from the helm to the inner transom from the pump to the control valve, and low
plate, an engine mounted pump, and a power pressure hoses (~) and (~ carry the fluid from
cylinder to movethe drive unit steering arm. valve to the oil cooler, and back to the reservoir.
I~ The hydraulic pump (~) is mounted on the e The steering cable casing ~) attaches to the
front of the engine and is belt driven by the steering cylinder valve.
crankshaft pulley. The reservoir fill cap has a
dipstick attached. ¯ The cable ram passes thru the valve and
attaches to the clevis ®. The drive steering arm
e The control valve and cylinder ® is a single unit (~) is also attached to the clevis.
mountedto the inner transom shield.
7-4 Englne/eng
STARBOARD ,~ PORT
DR3506
System Operation SteeringTo Port - SteeringWheelTurningTo

Left
NoSteeringInput - SteeringWheelNot Turning
EEl When the helmis turned to port (either turning
When there is no steering input from the helm, boat to left or straighteningfrom a right turn) the
the spring @in the control valve keepsthe spool steering armis pulled to starboard. Thesteering
cable casingpushesthe valve spool ®to port. Fluid
® centered. Fluid from the pumpenters the con-
trol valvethru the pressureport L~), flows pastboth from the pumpenters the valve at O, is routed to
cylinder ports ~) and®with little restriction, then the rod-end outlet ®, and to the low volumeside
thru the return port @and back to the reservoir. of the cylinder @. The pumppressure movesthe
There is a small equal force at both ends®and @ piston andsteering armto starboard. Fluid in the
of the cylinder andthe cylinder doesnot move. high volumeside of the cylinder ® is forced out
thru the valve from ~ to return port @andback to
the reservoir. As long as the helmis turning to port
With no steering input, the outdrive is held in one
this motioncontinues,swingingthe outdriveto port.
position and the boat movesin a constant turn or
in a straight line.
When the helminput stops (steering wheelnot turn-
ing), the steering cable stopspulling the steering
arm to starboard, and the steering casing stops
pushingthe valve .,;pool to port. Whenthe spring
@movesthe valve spool to a "centered" position,
hydraulic fluid is again routed past both cylinder
outlets. Thesteering cylinder has an equal force at
both ends and stops moving. Thesteering system
is thq._.n backto the NoSteeringinput condition
describedpreviously.
E.~J~/..o 7-5
STARBOARD PORT STARBOARD PORT
O
DR3509 DR3507
Steering To Starboard - Steering WheeJ Steering W’~hout PowerAssist

Turning To Right
E~ if the steering system is not providing pow-
~] Whenthe helm is turned to starboard (either er assist, the operator maystill steer the boat.
turning boat to right or straightening from a left Turning the steering wheel to port causes the
turn), the steering arm is pushed to port, The steering cable fo pu[J the steering arm to star-
steering cable casing pulls the valve spoot (~ to board. This causes the cable casing to push the
starboard. Fluid from the pumpenters the valve valve spool (~) to port against the stop about
at O and is routed to the piston-end outlet @)and 0.125 in. (3,18 ram). The steering cable then
to the high volume side of the cylinder (D. The transmits the full manualeffort to pull the steer-
pump pressure moves the piston and steering ing arm.
arm to port. Fluid at the low voiume side of the
cylinder @is forced out and thru the valve from The fluid ® ahead of the piston is forced out of
to return port ~) and back to the reservoir. As the cylinder thru outlet ~) into the valve, and thru
long as the helm is turning to starboard this return port @back to the reservoir. Additional
motion continues, swinging the outdrive to star- fluid is drawnout of the reservoir thru the pres-
board. sure inlet O and (~) to the opposite side of the
piston ~).
Whenthe helm input stops (steering wheel not
turning), the steering cable stops pushing the More steering effort is required since all of the
steering arm to port, and the steering casing power required to steer the boat must be sup-
stops pulling the valve spool to starboard. When plied by the operator, and additional force is
the spring (~) movesthe valve spool to "c en- required to move the fluid through the system
tered" position, hydraulic fluid is again routed when the pump is not operating.
past both cylinder outlets. The steering cylinder
has an equal force at both ends and stops mov-
ing. The steering system is then back at the No
Steering Input condition described previously.
7-6 Engine/eng
®®@ ®/ ®
©
I-"
® ®
DR3007 DR3008
PumpOperation
EEl During normal operation, fluid is drawn into dual pump
intake ports ~) from the reservoir ®. Thereservoir is suppliedby
a low pressurereturn line © from the powersteering oil cooler.
The pumpoutput is thru ports (E). The vanes(E) are held
against the pumpbore by pressure behind the vanes. The pump
has sufficient output ® to allow quick boat maneuverseven at
engineidle RPM.Thepumpoutput at high RPM is limited to about
2.3 gallons per minuteby a flow restriction orifice @.
Thepumpoutput pressureis determinedby the resistance to flow

of the system. Whenno steering changesare being made,the
pressurewill be about 50-100PSI. Whenthere is steering input,
the pressurewill be higher andwill dependon the steering forces
required due to the boat attitude, drive trim position, throttle
position and quickness of the maneuver.
i[~ The pumpis protected from very high pressures by a
pressurerelief valve ® that is located in the pumpbody. If the
steering load becomesextremelyhigh, the relief valve willl open
andlimit the output pressure(~) to about 1,000-1,100PSI.
I~ Internal damageto the pumpwill occur if the system is
operatedat relief valve pressurefor morethan a few seconds.
![~] Thepumphas a metric output fitting. Useonly a hosewith a
metricfitting.
2635
E,oi,~,g 7-7
Pump Removal
[~ 1. Place an oil drain pan under pump.Disconnect high pres-

sure hose @and return hose ® at pump.Do not lose O-ring on
pressurehosefitting. Securehoseendsin a raised position to pre-
vent fluid draining from hoses. Capor tape endsof hosesto keep
out dirt. Drain pumpcompletelybefore removing.
~ [~3 2. Loosen pumpbracket mounting screws and re-

movedrive belt.
20497
o 3.0 GSModels [~
® 4.3 and 5.7 GL, Gi Models E~
¯ 5.0, 5.8 FL and Fi Models ~]
¯ 7.4, 8.2 GL, Gi, Models [~
3. Take out mountingscrews and removepumpfrom engine.
[~] 4. Removepumppulley using apulley remover, then remove

mountingbracket. 23916A
Pump
Installation
~] 1. Attach mounting bracket to pump. Attach pulley using a

pulleyinstaller.
2. Mountpumpbracket loosely on the engine.
[~ 3. Makesure O-ring is in place and in goodcondition, then

connecthigh pressurehosefitting @. Tighten fitting to 15-26ft.
Ibs. (20-35 N.m).
[~ 4. Connectreturn hose ® to reservoir. Tighten hose clamp

to 12-17in. Ibs. (1,4-2,0 N.m).
5. Fill pumpreservoir with Volvo Pentapowertrim/tilt & steering

fluid. Bleedpump,hoses,andvalve by turning pulley clockwise(as
viewedfrom front of engine) until reservoir no longer showsair
bubbles.Keepreservoir filled while purging air from system.
6. Install drive belt andadjust belt tension as describedunderBelt 24734A

Adjustmentin this section. Do not pry against pumpreservoir
while tighteningbelt.
7. Bleed entire systemas outlined under Purging Air FromSteer-

ing System.
Hydraulic Fluid
Usean approvedpowersteering fluid such as Volvo Penta power

trim/tilt & steeringfluid or GMPowerSteeringFluid. If thesefluids
20510
7-8 Englne/eng
CheckingFluid Level
I8~ 1. Run engine and rotate steering wheel lock-to-lock for a
reasonably long period of time to warmup steering fluid, then
shut engineoff. Removereservoir filUer cap and checkif fluid level
is at "HOT"mark on dipstick.
[_9~_ 2. if fluid level is low, add recommended hydraulic fluid to
bring fluid up to ’"HOT" mark on dipstick= Replacefiller cap.
[~ Do not over-fill a cold reservoir. Fluid could overflow when

system reaches operating temperature. 20847
Purging Air From Steering System

When system components have been serviced, pump m~ast be
refilled with fluid before engine is started. Perform the following
steps to purge air from the steering system.
Do not run pump even momentarily without fluid. Pump

will be ruined or severely damaged.
11. With engine "OFF," turn henmall the way to port. Add power
steering fluid to bring fluid level to "COLD"mark on dipstick. 20846
2. Start engine, run momentarily and shut off engine. Recheck

fluid level and fill to "COLD"mark. Repeatthis step as necessary
until systemno longer requires additional fluid.
3. Complete purging of air from system by starting engine and

turning wheel slowly lock-to-lock. Maintain fluid level above
pumpbody in reservoir.
4. Returning fluid with air in it will often be in the form of foam

and will have a light tan or red appearance.Maintain fluid level
high enoughso foam is not drawn into pumpinlet. AHair must be
20509
eliminated from fluid before normaU steering action can be
obtained, if excessive foam accumulates in reservoir it must be
removed, or let unit stand for an hour and repeat steps above.
5. After all air has beenpurged, return wheelto centered position.

Continue to run engine for severaU minutes and then shut engine
off.
6. With engine "OFF" and with fluid at normal operating tempera-

ture, recheck to makesure fluid level is at "HOT"markon dipstick.
7. Water test the boat to make sure the steering functions

normally and is free from noise. 31839
Engineleng 7-9
2391 DR4833 24278
Power Steering PumpBelt Adjustment
~’’"~[~ With engine stopped, the belt shoundbe tight enoughso

that it will deflect 1/4" to 1/2" (6-13mm)whenpressed
with the finger
the point indicatedO. If the belt is too tight, excessivebelt wearcan
occur.If it is too loose,slippagecanoccur,resulting in belt wearand
poor powersteering operation. Belt tension shouldbe checkedafter
10 hoursof service andevery50 hoursthereafter.
DR4935
® PowerSteering PumpPulley
® Circulating PumpPulley
® 1/4" - 1/2" (6-13mm)
Deflection
Checkpowersteering pumpbelt tension ® midwaybetweenthe cir-

culating pumppulley ® and the powersteering pumppulley O. Re-
tighten newbelt, or checkold belt after 10 hoursof serviceandevery
50 hoursthereafter.
,~CAUTION:Whenadjusting a powersteering pumpbelt, neverpry

againstthe pump
reservoiror pull againstthe filler neck. 15930
3.0 GS Modeas
[~ ~] Toincreasebelt tension:- Loosennut on lower pivot bolt,
andloosen screwon brace behindpulley. Place W’ breakerbar into
the squarehole in the pumpmountingbracket, and pivot pumpaway
from engineas shown.While maintainingpressureon pump,retighten
all mountingscrews.Recheckbelt tension.
4.3 GL, GS, Gi and 5.7 GL, Gi Modeas

DR4934
E~ [~] To increasebelt tension: - Loosenpumpmountingbracket
screws,insert a 1/2" breakerbar into the squareholein the pump
mount-
ing bracket, andpivot pumpawayfrom engineas shown.Whilemain-
taining pressureon pump,retighten all mountingscrews. Recheck
belt tension.
16067
9--q ©
DR2959 20572
All 5.0 and5.8 Models

[~] To increase belt tension: - Loosennut on lower pivot bolt,
and loosen screwon brace behind pulley. Place a 1/2" breaker bar into
the square hole in the pumpmounting bracket, and pivot pumpaway
from engine as shown.While maintaining pressure on pump,re[ighten
all mounting screws. Recheckbelt tension.
7.4 GL, Gi, GSi and8.2 GL, Gi Models

L-~ To increase belt tension: - Loosen mounting screws. Rotate 20606
bottom of pumpoutward by prying between the harmonic baJancer

and the bottom tab of the powersteering pumpsupport bracket.
Steering Cylinder
E~ The steering cylinder assembly is a combination power cylinder
and control valve. A piston rod clevis @provides the attachment to
the steering arm and steering cable ram. The steering cable casing
attaches to the threaded valve ®.
Cylinder Removal 20504
1. Turn the helm full lock to port. Remove

the cotter pin @and
the steering cable pin @.
2. Hold steering tube with wrench. Loosensteering cable anchor

nut ® and puff steering cable out of valve.
3. Remove
cotter pin, then pull pin ® out of clevis and steering
arm.
D3~] 4. Removeboth hose fittings @from valve. Raise hoses above

2058:
pumplevel and cover the endsto keepout dirt.
,~WARNING: Do not movecylinder in or out until cylinder ha,,; been

drained completely. A dangerousspray of fluid can discharge from
cyfinder ports if the rod is moved
in or out.
E.~i,~/.~ ~ Safety Related 7-11

®
20580 2O579
[~ 5. Removecotter pins (~ and loosen both anchor screws

until steering cylinder assembly can be removed.
Cylinder Servicing
[~ 1. Pry out steering pivot bushings © if they are to be

replaced, if necessary they maybe carefuJly drilled in two places
with a ~As in. (1,5 ram) drill bit and then removed.
2. Newbushings should be lubricated and pushed into place.

20576
3. The cylinder rod should be wrapped with heavy paper or
pasteboard and held in a vise with clamping blocks
P/N 3854367-4. To remove the clevis (~), unscrew the 19
Iocknut (~).
[~ Z~ 4. To reinstall clevis, tighten piston rod to clevis iocknut

® to a torque of 23-28 ft. Ibs, {31-38 N-m).
Cylinder installation
[~] 1. Install
shield.
anchor screws (~ flush with inside of inner transom
!
[~ 2. Apply Volvo Penta Grease to both bushings.
[~ Z~ 3. Position steering cylinder assembly on inner transom

shield. Align bushings of steering cylinder with screws. Hand
start both anchor screws to ensure alignment and engagement
into bushings. Tighten anchor screws to a torque of 40-45 ft, Ibs.
(54-61 N-m).
[~ ~ 4. Install cotter pins ~ through holes in transom shield

from transom side. Spread ends of cotter pins to secure.
A~ Do not move cylinder rod if cylinder contains any fluid. A 20574
dangerousspray of fluid maydischarge from the ports.
Z~ Safety Releted 7-12

®
20504 31837 20570
[’7~ 5. Connecthosesto cylinder. Start eachfitting by hand.Tighten

pressurefitting @to 10-12ft. Ibs. (-4-16N.m).Tightenreturn fitting
to 15-17ft. Ibs. (2--23 N.m).
E~z~ 6. Puli steering arm0 into hydraulic cylinder clevis ~). Align
holes andinstall large pin ® from top of arm. Securelarge pin by
installing andspreading endsof cotter pin.
CableInstallation
205O6
[~ Z~ 1. Turn the steering wheelto fully extendthe steering cable
ramto its maximum extension.Lubricatethe full lengthof the steer-
ing cable ramwith VolvoPentaGrease.
.~ 2. Retract steering cable ram(~ andinsert ramthroughvalve @.
[~ 3. Hold steering cable anchornut back on cable casing to make

certain the steeringcableis completelyseatedin endof valve.
[~2~] 4. Whileho{dingsteeringcabletight againstvalve, threadsteer-
ir~g cableanchornut ® onto valve until snug. 20606
[~10~] [~ Z~ 5. Hole cable tube with a 22 mmwrenchon the flat @.

Attach a crowfoot wrenchat 90° to a torque wrench® and ti~ghten
the steeringcableanchornut to a torque of 120in. Ibs. (14 N-m).
Z~ & Align cable ram(~ with steering cylinder clevis (~ and

install small pin fromtop of clevis. Secure
smallpin by inslLalling
andspreadingendsof cotter pin.
7 Fill systemwith fluid and removeall air. SeePurgingAir From

Steering System. 20605
Lubrication
I_~ .L=L~Every60 days,greasethe steeringramwith VolvoPenta

Grease.
,_.NoteDueto {ocal conditions, it maybe necessary
to lubricate your
engineat morefrequentintervals.
E,~ji~J.,~ Z~ SafetyRelated 7-13 20507

Hoses
[~ Do not start engine with any power steering hose discon-
nected.
The pumpoutput fitting has metric threads. Do not attach a hose

with SAEthreads to the pumpfitting.
After connecting power steering hoses, makesure that there’s

ample clearance between the hoses and drive belts and other
components. Hoses installed out of position may rub during
operation and be damaged.
if fluid return hose is removedat pump, be sure to use a "worm

drive" clamp whenreinstalling it.
System Diagnosis
Complaints of faulty steering are frequently the result of prob-
lems other than the steering cylinder assembly or pump. Condi-
tions such as hard or loose steering, or vibrations, are often
related to such factors as the drive belt; pump and cylinder
mounting; fluid tevel; or incorrect installation of the steering
cable. These factors should be checked and corrected before
disassembJingor replacing parts of the steering system.
System Checks
Manyfactors affect power operation of the steering system. Some

of the most commonproblem areas are:
¯ Fluid level.
¯ Looseor worn drive belt, or oily belt.
¯ Steering cable jammed against something in boat at

stern.
¯ Steering cable too short or steering cable too long.
¯ Loosely mounted components.
e Loose pump pulley.
After the problem has been found, determine the cause. For
example,if the fluid level in the reservoir is found to be low, refill
and bleed the system and check the entire hydraulic system for
leaks. Just refilling the reservoir will makethe unit operate, but
will not correct the condition that caused the problem.
Trim Tab Adjustment - SX Models
Models With Power Steering
Power steering models should not have trim tabs. if equipped,

trim tab should be replaced with the trim tab hole plug Volvo
Penta P/N 3850662-2.
Models Without Power Steering
The trim tab should be preset to dimension ~) 31/~ in. (83

mm), (5 ° ® for left-hand rotation) and dimension © 21/4 in. (57
rnm), (30° ¢~ for right-hand rotation). They should remain at this
setting for all applications.
If the trim tab is NOTset correctly, movetrim tab to the correct

position. Tighten the trim tab screw to a torque of 28-32 ft. Ibs.
(38-43 N.m).
The boat maybe slightly easier to steer in one direction or the

other due to steering forces or other reasons. To adjust, preset the
trim to the dimensions above for models with power steering.
Thencheck by running the boat in a straight line with a balanced
load in an area where current and wind will not be a factor. To
obtain equal steering effort, adjust the trim tab as follows:
Safety Warning: improper trim tab adjustment can cause

difficult steering.
1. Turn the steering wheel in both directions to determine the

direction that requires the least amountof steering effort.
2. Loosenthe trim tab bolt and if less steering effort is required to

port, movethe trim tab slightly to port. if less steering effort is
required to starboard, movethe trim tab slightly to starboard.
Twin engine installations require both trim tabs be moved an
DR4931
equal amountin the samedirection.
3. For twin engine installations wheretrim tabs are used, set both
trim tabs to the sameposition.
4. Retighten trim tab bolt and recheck steering effort in both

directions. Repeatprocedure until steering effort is equal in both
directions.
5. After final adjustment, retighten the trim tab screw to 28-32 ft.
Ibs. (38-43 N.m).
En~ow//~ Safety Related 7-15

Power Steering SystemDiagnosis Chart
Condition Possible Cause Correction
SYSTEMNOISE:
Pumpnoise "chirp." Loosebelt, Adjust belt tension to specification.
Belt squeal. Loosebelt. Adjust belt tension to specification,

"Hissing" sound. Somenoise exists in all powersteer- None; a slight "hiss" is normal and in
ing systems. "Hiss"may be expected no wayaffects steering.
whenturning the steering wheel, par-
ticularly at low speed.
Rattle Pressurehose touching other parts of Adjust hoseposition.

engine.
Rattle or chuckle. Steering systemlooseness. Check cable nut and cylinder pivot
points for wearor looseness.
Replacebushingsif necessary.
Groan Lowfluid level. Find and repair leak. Fill reservoir and
bleed system.
Air in fluid. Fill reservoir, find andrepair leak.
Checkconnections, bleed system.
Growl Excessive back pressure caused by Locate restriction and correct. Replace
hoserestriction, part if necessary.
Pumpgrowl. Incorrect steering cable adjustment. Adjust cable per procedure. Eliminate
Cableto boat interference, interference.
Whine in pump. Pumpshaft bearing scored. Flush system, replace pump.
SYSTEMOPERATION:
Excessivewheel kickback or Steering cable attachment loose. Replacepin. Tighten steering cable an-
loose steering (not boat chornut.
wander).
Air in system. Add fluid to pumpreservoir and bleed
system.Checkall connections.
Steering wheel surges or Loose pumpbelt. Adjust tension to specification.

jerks whenturning with en-
gine running, especially Air in fluid. Fill reservoir, find andrepair leak.
during slow speed opera- Bleed system.
tion. Insufficient pumppressure. Replacepumpif defective.
Momentaryincrease in ef- Pumpbelt slipping. Tightenor replacebelt. If oily, fix leak.

fort whenturning wheelfast
to right or left. Lowfluid level. Fill reservoir and bleed system.
High internal leakage. Replacepumpif defective.

Condition Possible Cause Correction
Hardsteering or lack of as- High internal leakage. (Powercylinder Replacepumpif defective.

sist. or pump.) Replacecylinder if defective.
Cable jacket movementrestricted Do not clamp cable tight near output

(bulkhead, fuel tank, jammedagainst end. Eliminate interference.
inside of hull).
Loosepumpbelt. Adjust belt tension to specification.
Lowfluid level in reservoir. Fill to properlevel, if excessivelylow,

checkal~ lines andjoints for evidenceof
external leakage, torque to specs.
Lackof lubricant in lube points. Lubricate, relubricate at proper inter-

vals.
Excessivefriction in steering linkage. Find reasonfor excessivefriction;

relubricate or repair.
Cablehas too tight a radius at output Eliminate small radius.

end.
Cable movementrestricted by tie Remove all cable anchors, tie straps,
straps, anchors,attachedwires, etc. etc. on cable between last bend and
valve attachmentpoint.
Insufficient fluid pressure. Replacepumpif defective.
Hardsteering to starboard. Cable too long or movement

restricted Replacecable, or eliminate restriction.
by bulkhead,etc.
Hardsteering to port. Cable too short or movement:re- Replace,cable, or eliminate restriction.

stricted by bulkhead,etc.
Lowfluid pressure due to Checkfor kinks in hoses. Removekink.

restriction in hoses.
Foreignobject stuck in hose. Removerestricting object or replace
hose.
Lowfluid pressure due to Pressureloss in cylinder due to worn Replacecylinder assembly.
steering cylinder, piston ring or scored housingbore.
Low fluid pressure due to Loosebelt. Adjust tension to specification.
steering pump.
Lowfluid level. Find and repair leak. Fill reservoir and
bleed system.
Air in fluid. Fill reservoir, tighten fittings andhose
clamps. Bleed system.
Defective hoses. Correct as necessary.
Pumpworn or damaged Flush system, replace pump.
Foamingmilky powersteer- Air in fluid and loss of fluid due to Checkfo~ leak and correct. Bleed sys-
ing fluid, low level andpos- internal pumpleakage causing foam- tem. Keepfluid level up whenvery cold.
sible low pressure. ing and overflow. If fluid level is correct andpumpstill
foams, replace pump.
E~ng 7-1 7
External Leakage
General Procedure
1. Wipe suspected area dry.
2. Checkfor over-filled reservoir.
3. Checkfor fluid aeration and overflow.
4. Checkhose connections - tighten if necessary.
5. Determine exact point of leakage.
6. Whenservice is required, replace component.
Leakage Checks
Although someleaks are easily found, seepagetype leaks maybe

difficult to pinpoint. Locate seepageleaks as follows:
1. With the engine off, wipe the complete power steering

system dry (pump, hoses, and connections).
2. Check the fluid level in the pumpreservoir and adjust as

directed.
3. Start the engine and turn the steering wheel from stop-to-
stop several times.
4. Find the exact area of leakage.
Easily Fixed Leaks
1. Loose clamp on pump return hose.
2. Loose pump or cylinder hose fitting. If fittings are not

cross-threaded, tighten to correct torque. See Torque Speci-
fications.
3. DamagedO-ring on pumppressure fitting. Replace O-ring.
4. External meakageof power cylinder. Replace power cylinder.
5. Leakageof fluid in cooling water. Replaceoil cooler.
8. Damageor cracked hose. Replace hose.
if the return hose is removed, the clamp must be replaced with a

wormdrive clamp. Replace leaky hoses.
7-18 Engina/eng
,/
DR3009 DR1443
Pump Leakage 2. Removefiller cap from pump reservoir and

check: fluid level. Flit/pump reservoir to full mark
[~ 1. An over-filled pumpreservoir can cause a on dipstick. Start engine, momentarily hold
leak. The fluid in the steering systemexpandsas steering wheel against stop, and check connec-
it heats up during normal usage and fluid level tions at Tool J-5176 for leakage.
rises in reservoir. Excessfluid is forced through
the breather cap hole where it may be sprayed 3. Bleed system as outlined under Purging Air
over the engine by the drive belt. From Steering System.
[1~ 2. Install newO-ring. Tighten hose fitting 4. Insert thermometer Kent-Moore Tool J-5421
to 15-26 ft. Ibs. (20-32 N.m). If leakage persists, into reservoir filler opening. Start the engine and
replace pumpor hose as required. movesteering wheel from stop-to-stop several
times until thermometerindicates that hydraulic
[~ 3. Check torque on fitting (~). Tighten to fluid has reached its; normal operating tempera-
torque of 37-75 ft. Ibs. (50-102N-m). If fitting ture of approximately150° to 190° F (65° to 88° C).
not loose, replace pump.
5. Checkfluid level; add fluid if required. When
[1-7 4. Checkfluid level ©. If leakage persists engine is at normal operating temperature, the
with fluid at correct level and cap tight, replace pressure reading on the gauge (valve open)
cap or pump. should be in the 50-100 PSI (345-690 kPa) range.
if pre,ssure exceed,s specifications, check the
E~ 5. Somenon-repairable pump leakage areas hosesfor restrictions.
are markedwith the oil-drop symbol. If leakage
occurs in these areas, replace pump. Z~ 6. Pumprelief valve pressure can be checked
by momentarily closing the shutoff valve. Do riot
PumpPressure Test leave valve closed longer than it takes to read
gauge; high hydraulic pressures are developed.
r2~ 1. With engine off, disconnect high pressure Relief valve pressure is approximately 1000-1100
(output) hose at pump. Use a spare pressure PSI (6895-7584 kPa).
hose (~ to install Kent-Moore Tool J-5176 (~)
between pump and steering cylinder pressure Replace pumpif fluid pressures or temperature
hose (~). Gauge must be positioned between do not meet specifications.
shutoff valve and pump. Connect steering cylin-
der pressure hose to shutoff valve. Openshut-off
valve.
7-19
Cable Installation Problems
Thehydraulic valve reacts to steering cable casingmovement. Total ir

valve movement is about1/4 inch. This small motionis sufficient to
operatethe valve anddirect hydraulicpressureto the appropriateside
of the steering cylinder. Anyrestriction of movement of the steering
cablecasingat the sternof the boatwill limit or restrict the movement
of the valveandwill result in hardsteeringin oneor bothdirections.
Whenreplacingthe steering cable, the following points mustbe fol-

lowedfor properpowersteering systemoperation: DR1450
[~ 1. Donot install a cablethat is too short. Inadequate

length will
put tension on the cable casing, andcausebinding of the steering
cable. This will restrict valve movement,
causehard steering to port
anda tendencyto self steer to starboard.
2. Donot install a cablethat is too long. Excessive length will

pushon the cable casing, andcausebinding of the steering cable.
This will restrict valve movement, causehard steering to starboard
anda tendency to self steer to port.
DR1451
3. Donot position steering cablein a sharpbendof less than 6 in.
radius. Tight bendswill causebindingandlimit control valve move-
ment.This will contributeto hardor uneven
steering, or roughsteering
wheel movement.
[~ 4. Donot jam anything against cable at the engineend. Do not

bind cableagainstinside of boat or againstfuel tanks, battery boxes
or flotation blocks. Jamming
the steering cablewill restrict steering
cable movement and causehard steering.
E~ 5. Do not interfere with or restrict steering cable movement DR1452

throughthe last 90° of bendto the engine.Cableretainers,clips, clamps
or tie strapsshouldnot be usedin a manner that will restrict the cable
movement near the engine. Do not attach wiring harnessor control
cablesto this endof the steeringcable.
Z~Donot restrict steering cable casingmovement. Any restric-

tion of the cablealso restricts the vatvemovement.
Thiswill limit or
stop hydraulic assist, or mayhold the vanvein onesteeringmode.
SafetyRelated 7-20
FeedbackTo ’The Helm If the steering wheel turns to both starboard and
port, then helm friction must be increased
The steering system requires at least a little slightly. This will atlow the powersteering sys-
friction in the helm (and cable) to prevent hydro- tem to hold the desired steering position.
dynamic forces on the gearcase from feeding
back and turning the steering wheel without the If the helm always turns in one direction (whenit
operator activating the power assist system. This turns), it maybe causedby a steering cable that
mayhappenon single engine instaiJations (or on is too short, too long, or has restricted move-
twin engines having both drives rotating in the men1:. See Cable Installation Problems. Twin en-
samedirection). gine problems may be corrected by having the
drive,s rotate in opposite directions.
Runthe boat in a straight line in opposite direc-
tions at normal cruising speed with the drive
trimmed in both a "bow up" position and in a
"bow down" position. In each trim position,
momentarily release the steering wheel to see if
the wheel is turned by the gearcase, and in which
,direction.
Specifications
PowerSteering PumpRelief Valve Pressure (except 8.2 GL) ....... 1000-1100psi (6895-7584 kPa).
Torque Specifications
Component Torque
Anchor Screw - Cylinder assy. to TransomPlate 40-45 ft. ibs. (54-61 N-m)
Bolts - Power Steering PumpMounting Bracket 25 ft. Ibs. (34 N-m)
Bolts - Power Steering PumpMounting 25 ft. Ibs. (34 N-m)
Fitting - Power’ Steering Pump 37-75 ft. Ibs,. (50-102N-m)
Fitting - Power Steering PumpHose 15-26 ft. Ibs. (20-35 N-m)

Fitting - Inlet Control Valve Hose 10-12 ft. Ibs. (14-16 N-m)
Fitting - Outlet Control Valve Hose 15-17 ft. Ibs. (20-23 N-m)
Hose Clamps - Oil Cooler and Power Steering Pump 12-17 in. Ibs. (1,4-2,0 N-m)
Jam Nut - Anchor Block 35-40 ft. Ibs. (47-54 N-m)
Locknut - Piston Rod To Clevis 23-28 ft. Ibs. (31-38 N-m)
Nut - Steering Cable Anchor 120 in. Ibs. (14 N.m)
Screw- Trim ~zb 28-32 ft. Ibs. (38-43 N-m)
E,,~,i,~,g 7-21
NOTES
7-22
Section 8
Throttle andShift Controll Systems
Table of Contents
Volvo Penta Models
installation of SAECables
,~hlft Cable to Drive ................................... 8-3
Throttle Cable to Engine ............................... 8-5
Replacementof RemoteControl Cables ................. 8-6
Z~ Safety Warnings
Before working on any part of the engineor related systems, read the sec-
tion called Safety at the end of this manual.
the battery before working on electrical systemto prevent possible sparks
or arcing in the engine compartment.
Before starting engine after repair or maintenance procedure.,;, alwaysmake
sure enginecompartment is free of fuel vapor.,; to prevent possible fire and
explosion.
power steering pump, supply pump, and circulating pumpbelts, pulleys
and other movingparts.
Engine/eng 8-1
Materials Required
Volvo Penta Grease
Molybdenum Grease
Safety Warnings
Before working on any remote control system, read the section
called Safety at the end of this manual.
Replace any locking type fastener (example: iocknut or patch

screw) whoselocking feature becomesweak. Definite resistance
to turning must be felt or locking fastener is not suitable for
continued use. Replace only with authorized replacementpart or
equivalent,
The following text will cover the replacement of parts, repair and
testing of Volvo Penta remote controls used with Volvo Penta SX
stern drive applications.
No single test of the remote control after reassembly will, by

itself, always ensure a properly functioning unit. To ensure correct
assembly and operation, you must follow aii the assembly
instructions in this section.
8-2 Engine/eng
® ®
\
~045 34044 34041
installation of SAECablesto Engine/Drive
Shift Cableto Drive Unit installation

~: _--
Notel Remote
control shift andthrottle cablesmustbe SAEtype
cables
--Note-1. If the throttle cableis attachedto the throttle armand
anchorblock, remove it fromboth. Thethrottle cablemustbe dis-
c, onnectedfromthe throttle armprior to shift cableinstallationand 34039
adjustment to prevent"loading"the controlboxandadverselyaf-

fectingshift adjustments.
2. Notethe positionof small seal ~ andlarge seal ® onthe

shift cable. Removeandretain jamnut, smallseal, andlarge seal
fromthe shift cable.
[~ 3. Applya light coatingof VolvoPentaGreaseto the endof the

remotecontrolshift cablecasing.Slide shift cablethroughshift
cabletubeuntil it ,appearsonthe outsideof the transom.
34037
[~ 4. Foreaseof installationof shift cable,turn driveunit to port,

Reinstall the retained large seal (~ and small seal (~ onto the shift
cablein the samepositionas notedin step2,
[~ 5. Loosencable clampscrew@and pull clampout.
[-~ 6. Slide shift cablethrough

pivot housing
andfrive unit.
r_~ 7. Slide clampin fully, engaging

the shift cableanchorgroove.
~CAUTION:
Tighten clampscrew securely. 34038
~-~ ~, Safety Related 8-3

34427 34421 34425
[~ 8. Rotateshift lever to extendbelmcrank(~). Remove

cotter
pin, flat washer,andanchorpin (~).
9. Threadanchorpin halfwayonto remotecontrol cable end.
[~ 10. Rotate shift Ueverback to neutral detent position, then move

remotecontrol handleto its neutral detent position. Turnanchorpin
iN or OUTuntil it aligns with centerof bellcrankslot (~).
[~ 1 1. Install flat washerandcotter pin. 34424
~CAUTION
: Secureby’ spread/ncj end of cotter pin. Install jam nut
(~ andtighten securelyagainst cotter pin.
[~ 12. For left handrota~onpropellers, the bellcrank link mustbe
installed into the starboardhole(~) of the shift lever.
[~ 13. For right handpropellers, the bellcrank link mustbe installed
into the port hole(~ of the shift lever.
34426
34420
34423
SafetyRelated 8-4
34030 34423A 34419
E~[~ 14. To reposition bell crank link, removecotter pins @and

pin ® from clevis, then rotate linkage @out of bell crank.
[~ E~15. Install linkage @into opposite side of bell crank. In-

stall washerandcotter pin @.Position clevis on starboardside of
shift lever andinstall pin ® andcotter pin @.
[~ 16. Reinstall rear cover and securewith three original screws

@.
Throttle Cableto EngineInstallation 34031
Note Moveremote control handle to NEUTRAL detent position.

Turn propeller shaft and shift into the FORWARD gear detent posi-
tion, then pull HALFWAY BACKtowards NEUTRAL.This posi-
tions the control for proper throttle cable adjustment.Failure to
follow this procedurecan bind the shift linkage in the control, and
produce"hard shifting."
E~1. Align internal boss ® of trunnion with throttle cable groove

®. Presstrunnion on throttle cable until seated.
34112
iN£te I~ Carbureted Models Only: Engine anchor bracket may
havetwo sets of anchorblock holes. Thetop set (marked)is for
the 4Vcarburetor models,and the bottomset is for the 2Vcarbu-
®
reted models.
E~ 2. Install openend @of trunnion in anchor block. Install

screwin anchorMockand position throttle cable assemblyin se-
lected set of holes.
,~CAUTION
securely.
: Nut ® must be against the anchor bracket, tighten ®
34751
DR4977
Engme/eng
®
0R4978 DR4979 DR4980
DE]3. Install throttle armconnectoronto the throttle cable. Pult

connectorfroward O to removeall end play from throttle cable,
then turn the connectorin until holesalign with the throttle arm@.
¯ "kCAUTION ¯ Throttle arm connector O must have a minimumof

9 full turns of 1~ in. of throttle cablethreadengagement.
N°tel If throttle armconnectorhole cannot be adjusted to align
with the throttle arm,checkfor propercable installation in the re-
motecontrol box.
34428
[~] CarburetedModels-Install connector onto throttle arm.
,~,.CAUTION : Install washerandcotter pin ®, andsecureby spread-

ing end of cotter pin. Tighten jam nut @against connector.
Replacementof RemoteControl Cables
Should it becomenecessaryto removeor replace the remotecon-

trol cables, the attachmentat the engineis very important. Follow
these steps for removaland installation of remotecontrol cables.
Before beginning, shift remote control handle into NEUTRAL de- 34424
tent position; propeller shouldrotate freely.
Throttle Cable RemovalFromEngine
[~ 1. Removecotter pin and flat washer® or lock nut (~ from

throttle arm.
IT~ 2. Loosenanchor retainer nut ~ and rotate retainer @away
from cable trunnion. Remove
throttle cable from throttle armand
anchorbracket.
Shift CableRernovalFromDrive 34O38
[T~ 1. Removesterndrive rear cover. Removeflat washer and

cotter pin from anchor pin. Remove
jam nut ® from shift cable
core wire.
[~ 2. Remove anchor pin @from bell crank slot. Unscrewanchor
pin fromshift cablecore wire.
3. Loosenscrewand slide retainer out of shift cable anchor

groove. Remove
the shift cable from drive and transomshield.
8-6
Section9
Cooling System
Table of Contents
Components
Circulating Pump- Engine .................................... 9-17
Hoses, Clampsand Drain Plugs ............................... 9-16
Manifold and Elbows ........................................ 9-17
Thermostat ............................................... 9-16
SherwoodRaw Water Pump.................................. 9-18
Johnson RawWater Pump................................... 9-21
Description ................................................. 9-2
Draining
Engine Block or Exhaust Manifold .............................. 9-23
Pivot Housing ............................................. 9-24
PowerSteering Oil Coolers ................................... 9-24
Sherwood RawWater Pump.................................. 9-18
Johnson RawWater Pump................................... 9-21
Thermostat Replacement..................................... 9-25
Troubleshooting
isolating Problem ............................................ 9-4
Possibilities to Consider ...................................... 9-4
Problem Checkpoints ........................................ 9-6
Quiz the Customer........................................... 9-3
Water flow Diagrams
Drive Unit and TransomShield ................................. 9-8
3.0 GS .................................................... 9-9
4.3 GL, GS, 5.7GL ......................................... 9-10
5.0, 5.8 FL ................................................ 9-11
4.3, 5.7 Gi ................................................ 9-12
5.0, 5,8 Fi ................................................. 9-13
7.4,8.2 GL ............................................... 9-14
7.4, 8.2 Gi, GSi ............................................ 9-15
Safety Warnings
Before working on any part of the engine, read the section called Safety at
the end of this manual.

the battery before working on electrical system to prevent possible sparks
or arcing in the engine compartment.
Before starting engine after repair or maintenance procedures, always make

sure engine compartmentis free of fuel vapors to prevent possible fire and
explosion.

power steering pump, supply pump, and circulating pump belts, pulleys
and other moving parts.
Description Cooling water for the engine is picked up at the
water intakes on both sides of the lower gear
Water is supplied to the engine by meansof an unit. Water is pulled upward thru the lower gear
impeller type pump (raw-water pump). The raw- unit until it enters a water tube that transfers it to
’water supply pump is mounted on the engine. the upper gear unit.
Water suppled to the engine is circulated in the
engine by means of a centrifugal type pump Water is pulled through the upper gear unit water
(circulating pump). passage where it meets a nipple and hose at-
tached to the pivot housing. Water is routed
The raw-water pumpused on this model is a self through the transom shield assembly to a tube
priming impeller type. The pump is mounted on that’s mounted on the inside of the transom
the engine and belt driven. During low speed plate. From this tube the water is drawn through
operation the impeller functions as a positive a supply hose that’s connected to the inside
displacement pump. At higher speeds it func- nipple of the raw=water pump. Water exits the
tions as a combination centrifugam and positive outside nipple of the raw-water pump under
displacement pump. The shape of the housing pressure and carried through a hose to the inlet
and liner cause an eccentric action of the impeller nipple of the thermostat housing.
blades during engine operation. During periods
of high speed operation, the resistance of the The water is now carried downwardthrough the
water on its way through the pumpis sufficient to thermostat housing where it enters the flexible
prevent the ends of the impeller blades from hose which attaches to the inlet pipe of the
making contact and following the inside perime- circulating pump.This inlet pipe is a part of the
ter of the pumphousing. The blades merely flex pump cover and feeds the coolant into a low
in toward the center of the impeller to perform as pressure area located at the axis of the impeller.
a combination centrifugal and positive displace- Vaneson the rotating impeller cause the coolant
ment pump. to be thrown outward and into the cylinder block.
All Models: The circulating pumpis mountedon

the front of the cylinder block, it has a pulley
bolted to the pumpshaft hub at its forward end.
This in turn is driven by meansof a belt from the
crankshaft pulley. The pump shaft and bearing
assembly is pressed in the water pump housing.
The bearing is permanently lubricated during
manufacture and sealed to prevent loss of lubri-
cant and entry of dirt. The pumpis sealed against
coolant leakage by a non-adjustable seal assem-
bly pressed into the pumpcover.
The cooling Water flows rearward through the In the event the enginecooling water is cold, as
water jacket which surrounds each cylinder and in first starting up, the thermostatwill be closed
extends below the lower limit of piston ring and will not allow any of the water to pass
travel. After flowing the full lengthof the cylinder through for eventual discharge overboard, in-
block, the water is forced upwardthrough two stead, the water wilt be carried via the flexible
passagesand into the cylinder head(s). Thewa- hoseback to the circulating pumpfor recircula-
ter nowflows forward in the cylinder head(s) tion within the block. Whilethe water within the
cool the combustionchamberareas. At the for- bloclk is recirculating, the raw-water pumpis
wardendof the cylinder head(s), the water enters pumpingwater to the block. Since this water is
the thermostat housing, if the water within the not able to enter the cylinder block, it is neces-
block is sufficiently warmedup, the thermostat sary to provide a methodof discharge. This is
will be openand a portion of the water will be provided by the bypasspassagewithin the ther-
pumpedupward past the thermostat. The re- mos’tat housing, if this were not provided, the
mainderwill be returned via the flexible hoseto resullting water pressure would be enoughto
the water pumpfor recirculation within the en- force the thermostatoff its seat, resulting in a
gine block and heads. The water which was greatly increased warm-upperiod.
pumpedupward past the thermostat wilW enter
the hose(s) connectedto the thermostat housing Cooling System Troubleshooting
outlet(s) and travel to the manifold(s). At
point the water flows rearwardthroughthe mani- 1. Quiz Customer
for the Following
fold passages andinto the high-rise elbow.All of information:
the water that enters the high=rise elbowis mixed
with the exhaust gases prior to entering the a. Howold is unit, how many hours of
exhaust pipe(s) and hose(s). This mixture operation? (Wearand corrosion.)
exhaust gasesand water then enters the exhaust
passagesof the transom shield assembly,pivot b. Howlong has problem existed? (Gradu-
housing and drive unit where it is discharged al or sudden.)
under water.
C. Whatwere the operating conditions pri-
or to problem?(Freshor salt water, silty
or sandywater.)
d. Whatprevious repairs and service have
beenmadeon unit? (Tune-ups, impeller
replacement,etc.)
e. At what RPMdoes problem occur? (Low,

high.)
2, Possibilities That Must Be ConsideredFirst:
a. Temperature GaugeMalfunction.
¯ ~mproper or defective sender unit

¯ Malfunctioning gauge - Checkground wire - substitute
good gauge.
b. Engine Water Circulation PumpMalfunction.
¯ Loose alternator belt

® impeller vanes worn - replace pump.
® impeller shaft seal failure - replace pump.
c. VVater Intake Screens Blocked.
d. Ventilation - Marinegrowth on keel, huJl deformities, etc.
e. ignition Timing
¯ Running with retarded timing - Check timing.
3. isolating Cooling Problem:
a.Procedure - Replace water hose between thermostat

housing and the raw-water pump with clear plastic
hose. Operateunit in test tank or boat in water at RPMat
which overheat occurs.
[~ If operating unit in test tank, run motor in neutral. Some

test tanks maynot have sufficient water volume to allow running
engine in gear without creating turbulence. This can be picked up
by the water intake and misconstrued as evidence of a cooling
problem.
b. Results and Conclusions - No bubbles in hose, air/

exhaust is not entering cooling water. Bubbles in hose,
air/exhaust is entering cooling water.
c. Check for - Defective lower gear unit water tube guide

and seals; damagedwater tube grommet; leaking water
passage cover gasket; leaking impeller plate gasket or
impeller housing O-ring.
9-4 Engine/eng
ao Procedure - Disconnect water supply hose from thermo-
stat housing. Operateengine at specified idle RPIVI. Hold
end of hose level with the top of the engine.
Results and Conclusions - A 2-4 inch (5-10 cm) head

water discharge, water supply is good. If less than 2
inches (5 cm), look for source of water loss.
Checkfor - Blocked intake screens; damagedimpeller

housing O-ring or impeller plate gasket; broken or worn
impeller; defective pivot housing water passage O-ring
or water drain screw seal; loose pivot housing-to-gimbal
housing water hose clamps.
a. Procedure - Operate engine until indicated temperature

exceeds 160° . Touch hoses between thermostat and
exhaust rnanifolds.
b. Resuits and Conclusions - Hoses cold, thermostat is

stuck closed. Hoses warmor hot, thermostat is good.
c. Check for - Thermostat stuck open or closed, defective

thermostat O-ring, correct thermostat style for engine
type, clear thermostat housing bypass passage.
Procedure - Allow engine to cool. Replace water hose(s)

between thermostat housing and exhaust manifold(s)
with clear plastic hose. Operate unit at RPMat which
overheat occurs.
b° ltesults and Conclusions - No bubbles evident, head

gaskets not leaking. Bubbles evident, head gaskets leak-
ing.
c.Check for - Cylinder compression using appropriate

tester, water in engineoil, water in cylinders, spark plugs
wet with water.
Volvo Penta
Cooling System Problem Checkpoints
for All Engine Modelsand SX Drive Units
Numbersrefer to Cooling System Flow Diagrams.
0 intake Screen - Baockedwith debris.

(~ Water Tube Guide and Seal - nmproperiy sealed.
(~ Water Tube - Plugged with debris.
(~ Grommet- Deteriorated, improperly seated.
C~) Upper Gear Unit - Debris blocking passage, freeze damaged.
~) Pivot Housing Seal - Damaged,out of position, improperly

sealed.
® Nipple O-ring - Out of position, improperly sealed, dam-

aged.
® Nipple - Blocked by debris, freeze cracked.
® Water Hose and Clamps - Clamps loose, hose collapsed or

leaking.
[~J TransomShield Water Tube - Blocked by debris.
[] Raw-water Pump- Failed seal, corroded or bad bearings,

eroded impeller, leaking mounting gaskets or backing pnate.
[] Thermostat Housing - Corroded, restricted, or leaking gas-

ket.
[] Thermostat - Defective thermostat, or wrong type for en-

gine; improperly seated or damagedO-ring.
[] Belts- Loose, or worn and slipping.
[] Circulating Pump(Engine) - Failed seal, corroded or bad

bearings, eroded impeller, leaking mounting gaskets or
backing plate.
[] Cylinder Block Water Passages - Corrosion, slag, blocked
passagesor leaking core plugs.
[] Cylinder Head- Corrosion, slag, blocked passagesor leaking

gaskets.
[] Exhaust Manifold, Elbows, Gaskets and Hoses - Gaskets

improperly installed; corrosion, sand or slag in manifold
and elbows; hoses collapsed, burned through, or lea, king.
Exhaust Pipe and Seal - improperly sealed or installed,

leaking.
~] Bellows, Clamp and Retainer - Loose clamp, detached or

torn bellows.
Engine and Power Steering Oil Cooler - Restricted, or

cracked and leaking.
[] Intake Manifold - Crackedcasting, or leaking gasket(s).
In addition, check:
¯ Ignition Timing
® Boat Hull - Condition of hull, marine growth or ~Jnder-

hull equipment.
l~ Fittings protruding through hull may cause air bubble

streams which can be picked up by the lower gear unit and mixed
with incoming cooling water to cause an overheat condition.
For Duopropand DPXdrive units, refer to Duopropor DPX

Workshop manuals.
®
@
® @
®
~) From Transom Shield
(E) Water Flow With Warm Engine
© Bypass Passage
Water Flow With Cold Engine
Mechanical
Steering
® @
Power |
\ Steering
Mechanical
,Steering
Power
Steering
@
3.0 GS Modells
DR4595
Engine/eng 9-9
® From Transom ShieJd
® Water Flow With WarmEngine
© Bypass Passage
® Water Flow With Cold Engine
4.3 Models(Carbureted} @
DR5084
g-’l 0 Engme/eng
® From TransomShield
© Bypass Passage
@ Water Flow With Cold Engine
® @
\
_~)’~{~ 5.0 and 5.8 FL Models
DR5085
4.3 and5.7 Gi
C~FromTransomBracket
,~ water Flow With WarmEngine
(©BypassPassage
4.3 and 5.7 Gi Models @WaterFlow With Cold Engine
DR5070
(A~ From TransomShield
(~c~ BypassPassage
~ Water Flow With Cold Engine
5.0 and5.8 Fi Models
DR5068
9-13 Engine/on~
® From Transom Shield
® Water Flow, WarmEngine
© Bypass Passage
® Water Flow, Cold Engine
@
®
®
7.4, 8.2 GL Models
7.4, 8.2 Gi, GSiModels
Engirle/eng
9-15
Cooling System Components
For all models. No special tools required.
inspection Procedure: Examineall external cooling system com-

ponents for leaks, wear, deterioration, and damage.Check all
connections for tightness. Inspect hoses for cracks, checking or
deterioration.
Repair Procedure: Repair or replace as required.
Water supply hoses used for replacement must conform to

S.A.E. 20R3, cmassD-2.
¯ All 3.0, 4.3, 5.0, 5.7 and 5.8 Liter Models: A 160° thermo-
stat is standard.
¯ All 7.4 GL and 8.2 GL Models: A 140° thermostat is
standard.
DR3232
inspection Procedure: Check for proper rating and style, corro-
sion, restricted movement,or broken spring.
[~ [~ Test Procedure - All 3.0, 4.3, 5.0, 5.7 and 5.8 Uter
Models: Immersethe thermostat and a thermometer in a contain-
er of water. Heat water. Thermostat should start to open between
157-163° F, and should open to %2 in. (3,96 ram) minimum(~
182° F.
~-] Test Procedure: All 7.4 GL and 8.2 GL Mode|s: Immerse the
thermostat and a thermometer in a container of water. Heat
water. Thermostat should start to open between 138-142° F, and
should open to %2 in. (3,96 ram) minimumbetween 140-162° F. DR3051
°Thermostat
. has full flow at 162
¯ 3.0 GS Models rT]
e All V-6 and V-8 Models
Repair Procedure: None, replace unit.
E.Qi../e.~ 9-16
For all models.Nospecial tools required.
Inspection Procedure: Pressure check componentsfor leaks.
Disassembleand inspect for corrosion or accumulationof foreign
material.
Repair Procedure:Rod out any accumulation of foreign matter
built up in water passages.If evidenceof porosity betweenwater
passagesand exhaust chambersor exterior is found, replace
component.Install newgaskets on reassembly.
For all models.Nospecial tools required.
inspection Procedure:Makesure belt tension is correct. Wiith the

engine running, observe the rotation of the circulating pump
pulley. If the pulley doesnot run true it can causeexcessivedrive
belt wearand damage to the circulating pumpitself.
l’r the leakageof water occurs at the circulating pumpwhile the

engine is in operation, the pumpmaybe loosely mountedto the
engine, the shaft seal in front of the pumpmaybe bad, the
backing plate gasket maybe defective, or the circulating pump
mountinggaskets are leaking.
If the aboveinspections do not detect any defect, the pumpmust
be removedand inspected for internal corrosion, blockage, or
damage,mnspectimpeller for erosion.
Repair Procedure: None, replace the pump.
Volvo Penta marine engines have a special circulating

water pumpwith stainless steel componentsand a special marine
shaft seal assembly. Do not replace with an automotive water
pump.
9-17
Removal
1. Drainengine,refer to DrainingEngineBlockor ExhaustMani-

fold.
[~] 2. Loosenhose clampsand removehosesfrom raw-waterpump.

Note:Theinside hose® is the inlet hose.
33857
[~ 3. Loosenpumpto bracket mountingscrews ® and removedrive

belt.
4. Removemounting screws and removepumpassembly.
Disassembly
[~] 1 Removethe three screws© securing impeller housingto bear-

ing housingand separate.
[~ 2. To separateimpeller housingfrom bearinghousing,hold shaft 33857A
while lifting andturning impeller housingcounter-clockwise.
[~ 3. if the impeller remainsin housing,graspwith pliers, pull and

turn counter-clockwise.
[~ 4. RemoveO-ring and discard.
[~5. Removescrew and seal washer securing cam and remove

cam.Refer to CleaningandInspectionbefore removingcam.
[~ 6. Pull impeller fromshaft, if requiredandremove

drive key@. 35349
[~] 7. Remove
end plate andgasket. Discard gasket.
35350
9-18 ~8
35362 35363 35353
r.~ 8. With a #1 retaining ring pliers, remove retaining ring

securing seal assembly.
~!~1 9. Removeceramic seal assembly.
Do not attempt to disassemble further. The pulley, impel-

ler shaft bearings and housing are serviced as an assembly.
Cleaning and inspection
1. Clean all parts with solvent and blow dry thoroughly.

35354
2. Removeold gasket as required from end plate and bearing

housing.
3. Clean O-ring groove and sealing surfaces.
4. Inspect impeller housing and camfor wear, and housing for

cracks and distortion caused by freezing. Replace if necessary. Do
not removecam if not required.
5. Inspect end plate; check impeller contact surface for wear,

scoring or distortion caused by freezing. If only worn,-do not
discard. Turn plate over and use other side when reassembling. 35356
6. inspect impeller; if blades are set in a bent position, cracked or

broken, or show flat instead of rounded edges on the housing
contact surfaces, replace the impeller.
7. inspect ceramic seal surface for wear and cracks. Replace if

worn or cracked.
8. Checkbearings ’for smoothoperation.
35357
9-19 Engine/eng
35358 35359 35360
Assembly
[~] [~ 1. Install ceramic seal assembly. Secure by pushing

retaining ring and seal assemblyonto shaft until retaining ring
snaps into groove.
Do not lubricate ceramic seal with grease.
EEl 2. Install drive key.
EEl 3. Apply a light coat of Gasket Sealing Compoundto the 35354

bearing housing gasket surface to hold gasket. Install end plate
and newgasket. There is no orientation of the plate and gasket to
bearing housing.
DE] 4. Install impeller onto shaft and key,
EEl 5. if impeller housing cam was removed, install new seal

washer on screw then apply Gasket Sealing Compound to
threads. Position cam in housing; install screw and tighten
securely.
6. Apply a light coat of Volvo Penta Grease to the impeller 35352

surfaces and O-ring groove of impeller housing. Install new
O-ring seal.
7. install impeller housing by rotating counter-clockwise onto

impeller.
EEl 8. Orient impeller housing by rotating until assembly screw

(~) next to the boss (E) is aligned with the mounting hole by
cam screw © as shown. Install the three screws and washers,
tighten securely.
installation
EEl 1. Orient pump assembly to the pumpbracket with the cam

screw (~)up. Install mounting screws and belt. Refer to Raw-water
PumpBelt Adjustment in the General information Section.
2. Attach the inlet hoseto the inside nipple and the outlet hose to
the outside nipple. Tighten hose clamps securely,
35367
Removal
1. Drainengine,refer to DrainingEngineBlock or ExhaustMani-

fold.
E~ 2. Loosenhoseclampsand removehosesfrom supply pump.

42865
l Notei Theinside hose@is the inlet hose.
E2~] 3. Loosenpumpto bracket mountingscrews ® and remove
drive belt. Remove
mountingscrews and removepumpassern-
bly.
Impeller Removal
[~ 1. Remove
the three screws© securing the end cover.
2. Remove
and discard gasket. 42864
E~3. Graspimpeller securely andpull from housing.
Cleaningand inspection
1. Cleanall parts with solventandblowdry thoroughly.
2. Remove any old gasket from end cover and housing. Clean
sealing surfaces.
39149
3. Inspect impeller housingandcamfor wear, and housingfor
cracksanddistortion causedby freezing. Replaceif necessary.
Donot removecamif not required.
4. Inspect endcover; checkimpeJlercontact surface for wear,

scoring, or dEstortioncausedby freezing. Replace
if necessary.
5. Inspectimpeller;if bladesare set in a bentposition,cracked,or

broken, or showflat instead of roundededgeson the housing
contactsurfaces,replacethe impeller.
39150
6. Checkbearingsfor smoothoperation.
39151
9 - 21 Engine/eng
39152 39154 39155
Impellerinstallation - V-6 andV-8 Models
[~ 1. Apply a light coat of Volvo PentaGreaseto impeller

surfaces.Install impeller until flush with surface.
[~ 2. Install newgasket without sealant.
3. Install end cover and secure with screws. Tighten

screwssecurely.
42865
Installation
L3J 1. Orient pumpassemblyto the pumpbracket with the

camscrew @up. install mountingscrewsand belt. Refer to
SupplyPumpBeltAdjustmentin the GeneralInformation Sec-
tion.
2. Attach the inlet hoseto the inside nipple and the outlet
hoseto the outside nipple. Tighten hoseclampssecurely.
37902
23907
23913
Englne/eng
9-22
33857 22423 23913
Draining Engine Block or Exhaust Manifold
Someservice work performedon the engine block and exhaustmani-

fold mayrequire the completedrainage of those components.
Note iI All Fuelinjection Models Only:Drain the small water by-
passhosebetweenfuel reservoir andthe top of the thermostathous-
ing. Disconnecthoseat the reservoir side of the checkvalve. Blow
out water in both directions. Inspect checkvalve for debris, then
reassemble.
28288
3.0 Models
E~ 1. Removethe long supply hose at thermostat housing ®.
Lowerit alongsidethe cylinder block anddrain it completely.
[~] 2o Disconnectand drain large hose ® at water pump.
[~ 3. Remove the drain plugs from cylinder block port side @and
exhaust manifold ®. Clear holes with a small wire to ensurecom-
plete drainage.
28287
4.3 and 5.7 Models
[~ 1, Remove the long water supply hose at the thermostat hous-
ing C). Lowerit alongsidethe cylinder blockanddrain it completely.
[~] 2. Disconnectand drain the large hoseat the water pump@.
[~] 3. Remove hose ® from port at starboard exhaust manifolds.

Remove drain ptugs (D on the port andstarboardsides of the cylin-
der block. Cleanholes with a small wire to ensurecompletedrain-
age.
24859
5.0 and 5.8 Models
Remove the long water supply hose at the thermostat hous-

ing ~). Lowerit alongsidethe cylinder blockanddrain it completely.
Disconnectand drain the large hoseat the water pump®.
Remove hose @from the port and starboard exhaust mani-

folds. Remove the drain plugs ® on both sides of the cylinder
block. Clear holes with a small wire to ensurecompletedrainage.
9-23 24076
Engine/eng
34161 28251 28283
[~ All Fuel injection ModelsOnly: Drain the small water bypass

hose(~ betweenfuel reservoir and the top of the thermostathous-
ing. Disconnecthoseat the reservoir side of the checkvalve. Blow
out water in both directions, inspect checkvalve for debris, then
reassemble.
7.4, 8.2 GLModels
DE] 1. Remove the long water supply hoseat the thermostat hous-
ing ®. Lowerit alongsideblock anddrain it completely.
28284
2. Disconnectand drain the large hose at the water pump©u

~ 3. Removehose @at front of each port and starboard
exhaustmanifold, and removedrain plugs <~ on both sides of the
cylinder block. Clear holes with a small wire to ensurecomplete
drainage.
DrainingPowerStering Oil Coolers
[~ Remove the lowest water hosefor the powersteering oil cooler.

If oil cooler is mountedhorozontally, removeone water from the 15819
cooler ®. Loosenthe cooler mounting bracket @and tip cooler

downward to drain.
Draining Raw-WaterPump
[~ 1. Loosenand slide hose clamps back. Removehoses from

the rear of pumpanddrain.
2. Crank the engine no more than 2 seconds, (DONOTSTART)

expel any water trapped in water pump.Reattach hoses.
33857
Draining Pivot Housing
~] 1. Tilt drive unit to the full tilt up position andremove

the water
drain plug ® from the port side of the pivot housing.
2. Tilt the drive unit to the full tilt down

position.Allowunit to drain.
After unit has completelydrained, replace pivot housingplug.
8--] 32351
/
J Failure to ensurecompletedrainageof the coolingsystem
mayresult in seriousdamageto the engineand/ordrive unit if un-
drainedwaterfreezes.
Thermostat Replacement
3.0 Models
[~ 1. Removeboth water hoses(i) and alternator brace (,~ from
upper thermostat housing.
14635
L~ 2. Takeout four mountingscrews and removethe upper ther-
mostat housing.
[~ 3. Remove and discard upper thermostat housing gasket, then
lift out thermostat. Removeanddiscard cork seal ®.
4. Thoroughlyclean both gasket surfaces, then insert a new

cork seal into housing. Donot apply sealer to cork seal. Install
thermostat in housing with temperaturesensing element(D down.
’l~ 5. Coat both sides of a newgasket with GasketSealing Com-
pound.Properly align the four screwholes and water bypassopen- 14633
ing (~, then place gasket on housing.

6. Install upperhousingandtighten four mountingscrewsto 5-7 ft.
Ibs. (7-9 Nm).
[’~ 7. Attach both water hoses® and alternator brace @.Tighten
the hose clampsand brace mountingscrew securely.
32350
All GMV-6 and V-8 Models
[~ 1. Removefour water hoses @from the thermostat housing.
Note] For Gi and GSi Models, you must removefive hoses from
the thermostathousing.
[~ 2. Removetwo screws®, and lifting eye, and lift off thermo-

stat housing.
[~ 3. Thethermostat@is held in place by an O-ring. Pry the 28546

O-ring out of its groove,then lift the thermostatout of the housing.
4. Discard the housing gasket and O-ring. Thoroughlyclean the

housing and manifold gasket surfaces.
5. Place the thermostat in the housing. The temperature

sensing element © must face you wheninstalled. Install a new
O-ring to seal thermostatin housing.Makesure O-ring is completely
seatedin its groove.
6. Coat both sides of a newgasket with GasketSealing Compound

andplaceit on the manifold.Install the housingandlifting eyewith
two screwsandlock washers.Tighten the screwsto 20--25 ft. Ibs.
(27-34 N.m).
7. Connectthe water supply hose to nipple @and tighten

hoseclampsecurely. Connectthe three remainingwater hosesand
tighten hoseclampssecurely. Makesure lifting eye @is positioned
as shown.
-Note, If the water supply hose is attached to the wrongnipple,
the enginewill overheat.
2854,7
9-26 Eng~ne/eng
All Ford Models
1. Remove
all water hosesattached to thermostat housing.
¯ Carburetor Models: four hoses ® rs]

¯ Fi and FSi Models: five hoses ® [-6-]
E~] 2. All Models: Remove the two screws @and lifting eye, and
lift off thermostathousing.
22417
[~] 3. The thermostat is held in place by an O-ring @. Pry the
O-ringout of its groove,then lift thermostatout of housing.
4. Discard housinggasket and O-ring. Thoroughlyclean the hous-

ing and adapter gasket surfaces.
[~] 5. Place thermostat in housing. Thetemperaturesensing ele-

ment® mustface you wheninstalled. Install a newO-ring to seal
the thermostat in housing. Makesure O-ring is completely seated
in its groove.
32348
6. Coat both sides of a newgasket with GasketSealing Com-
poundandplaceit on the adapter.Install the housingwith two screws
© andlock washers.Makesure lifting eye @is positionedas shown.
Tightenthe screwsto 20--25ft. Ibs. (27-34N.m).
. All Models
E~] [~ 7. Connect water supply hose to nipple @and tighten
hose clampsecurely. Connectremaining water hosesand tighten
hoseclampssecurely.
.......Note ~lf the watersupplyhoseis attachedto the wrongnipple, 2241
the enginewill overheat.
14649
|:’ngine/eng 9-27
NOTES
Section 10
Engine Removaland Installation

Volvo Penta SX Models
Table of Contents
Engine
Alignment ..................................... 10-7
Installation .................................... 10-6
Removal ...................................... 10-2
Determining Minimum Engine Height ................. 10-12
Engine Mounts, Rear .............................. 10-11
Exhaust Pipe Replacement .......................... 10-6
VolvoPentaSpecial Tools
PIN Description
3851083-0 Volvo Penta Alignment Tool

3850609-3 Volvo Penta Drive Handle
Sealants, LubricantsandAdhesives
Volvo Penta Grease
3M adhesive or equivalent
L~ Safety Warnings
Before beginning work in this section, r,sad Safety chapter at end
of this manual.
Proper installation is important for the safe, reliable operation of

all mechanical products. The procedures we recommend and
describe in these instructions are effective methodsto be fol-
lowed when installing Volvo Penta SX stern drive products.
Some of these methods require the use of tools specially
designed for the purpose. The special tools should be used when
and as recommended.
EngineRernoval
Before removing engine, check engine height. See Deter-
mining MinimumEngine Height.
Check engine clearance between front of engine and engine

compartmentbulkhead prior to starting work. if clearance is less
than 6 in. (15,2 cm), the drive unit must be removedto disengage
U-joint shaft from engine coupler. See Drive Unit and Transom
Shield WorkshopManual.
Whenengine clearance is more than 6 in. (15,2 cm), the engine 22703
can be pulled forward to disengage the U-joint shaft from the

flywheel coupler, and be removed from the engine compartment.
[~ Drive can remain installed only if engine removal does not

require disturbing engine mount height, and engine crankshaft is
not rotated. If mount height would need to be changed, or
driveshaft/coupler splines becomemisaligned because of crank-
shaft rotation, removedrive also.
,/~ To prevent possible fire and expJosioncausedby ignition of
fuel vapors which maybe present in the engine compartment,
removethe positive and negative cables from the battery. 22704
Battery Disconnection
~,~ Disconnect the red (positive) end black (negative) cables at

the battery.
[~ The key switch must be in the "OFF" position to safeguard

against permanent damageto electrical components while con-
necting or disconnecting the battery cables.
Power Steering Line Disconnection

[~ 1. Disconnect both power steering lines at the steering 22706
cylinder.
~ 2. If original steering line connector is available, use it

to link both steering lines together. If Connectoris not used, cover
both steering cylinder openings and line fittings to prevent fluid
loss and entry of contaminants. Tie lines onto engine higher than
power steering pumpto prevent damageand loss of oil during
engine removal.
Fuel Supply Disconnection
[~ ~ Disconnect boat fuel line at the fuel filter inlet. SeaJ end 2913
of fuel line and inlet opening.

~
¯ ,i
Electrical Cable Disconnection
[~ 1. All Mode|s: Disconnect the plastic two-wire trim/tilt motor
connector(~).
31461
33727 31460
L~ 2. Removewire retainer ® and unplug rubber two-wire trim/

tilt senderconnector.Cut tie strap © securingsendercable, if re-
quired.
["~""’~[~] 3. Unscrewclampand disconnect large rubber instru-

mentcable connector@. Unplugrubber three=wire trim/tilt cable
c, onnector®. All modelsexcept MPI,removereceptacle from elec-
trical bracket.
¯ Carburetor, Gi, and GSi Models E! ® 29790
¯ Fi and FSi Models E~l [~
Throttle CableDisconnection ®
[-~ [~ 1. Removecotter pin and fiat washer ® or lock nut @
from throttle arm.
[~ 2. Loosenanchorretainer nut ® and rotate retainer (~)

awayfrom cable trunnion. Remove
throttle cable from throt:le arm
and anchorbracket. O OR497~
¯ Carburetor, and TBi, Models ~1
- Fi and FSi Models ~1
, 7.4, 8.2 Gi, GSi Models ~J
DR4980
ExhaustHoseDisengagement
- 3.0 Models
E~ 1. Loosen four hose clamps.
DE] 2. For ease of movinghose, lubricate exhaustpipe.
[~ 3. To free exhausthose from elbow, pry or twist hose. Slide

hose downonto exhaust pipe.
ExhaustHoseDisengagement
- A|| V-6 and V-8 Models
[~ 1. Loosenfour clamps~) on lower exhaust hose. For ease of 6361
movinglower hose, lubricate exhaust pipe.
2. To free lower hose from intermediate pipe, pry or twist

hose. Slide hose downonto exhaust pipe (~.
6362
6363
17370
~737~
10-4 Engine/eng
Water Hose Removal
J~-] Loosen dampand pull water supply hose offtransom shield

water tube.
Engine Mount Separation
~ 1. Attach a hoist to lifting brackets of engine. Hoist must

havea lifting capacityof at least 1500Ibs. (680 kg).
2. Removeand retain both lock nuts © and both flat washers

@from rear engine mounts. 22698
I~ ~ 3. Remove and retain lag screws from front engine

mounts.
e 3.0 Models [~
¯ All V-6 and V-8 Models
4. If drive unit was removed, lift engine out of engine compart-

ment. If drive unit was not removed,lift engine slightly and pull it
forward to disengage U-joint shaft and flywheel coupler. With
U-joint shaft clear’ of flywheel coupler, lift engine out of compart- 33959
ment.
12211
2888
2933
Engineleng ~ Safety Related 10-5
Exhaust Pipe Replacement
Removal
1. Removeengine following previous procedure.
[~ 2. Remove and retain four exhaust pipe screws. Remove

exhaust pipe and discard seal (~). Clean all material from transom
shield and exhaust pipe seal surfaces.
Exhaust pipe mounting holes have locking Hell-Coil® in-

serts. Do not clean screw holes with a thread tapping tool, 22780
otherwise locking feature will be destroyed and Heli-Coflwill have

to be replaced.
Installation
1. Coat a new seal with 3M adhesive or equivalent and place

in transom shield groove ®.
[~ 2. Apply Gasket Sealing Compoundto the four exhaust pipe

mounting screws ©.
I~] 3. Secure exhaust pipe (~) to transom shield with four 15048
screws. Tighten to 20-25 ft. Ibs. (27-34 N-m). Slide exhaust hoses
and clamps (~) onto exhaust pipes if they were removed.
4. Install engine.
EngineInstallation
Engine Mount Attachment
1. Lower engine into engine compartment:
if drive unit was not removed, and engine crankshaft was 15047
not rotated, engage U-joint shaft with engine coupler
and slide engine back onto rear mounts, if coupmerand
U-joint shaft will not align, either the engine or U-joint
shaft will have to be rotated to allow engagement. If
engine mount height was disturbed, engine must be
realigned as described later.
¯ if drive unit has been removed, lower engine onto rear

mounts.
2. Install flat washers® into recesses of engine bracket and

secure engine to mount with lock nuts (~). Tighten lock nuts
~2212
28-30 ft. Ibs. (38-40 N-m).
[~ I-~ 3. install forward engine mountlag screwsand ’tighten
themsecurely.
¯ 3.0 Models
=
=
¯ All V-6 and V-8 Models
If drive unit was not removed,go on to Exhaust HoseAttach- m

mont. If drive unit wasremoved,continue with EngineAlignment
section.
Engine Alignment 2888
[~ Correct engine alignment is essential to long engine drive-

train life. The front engine mountsmayneedadjustment UPor
DOWN to produce correct engine alignment. Use Volvo Penta
Alignment Tool P/N 3851083-0with Volvo Penta Drive HandleP/N
3850609-3to check engine alignment.
~-~ 1. Slide alignment tool ® through driveshaft gimbal bearing
~. Thealignment tool must slide through the gimbal bearing and
into engine coupler with ease. If the alignmenttool binds going
into engine coupler, makesure the gimbal bearing is properly
aligned. If gimbalbearingalignmentis correct, the front ,engine 2933
mountsmust be adjusted either UPor DOWN, as required, until
alignmenttool slides easily in and out of enginecoupler.
~] ~1 2. To changeengine height, tighten or loosen nuts (~)
and (~) as required. Seerespective engine section, Front Mount
Height Adjustment.
¯ 3.0 Models [~
¯ All V-6 and V-8 Models [~
3. After correct alignment has been made,the front mount(s)

=mustbe tightened to maintain alignment. 34O6O
3.0 Models - While holding one nut with an open-end

wrench,tighten the secondadjusting nut to a torque of
115-140ft. Ibs. (156-190N-m).
e V-6 and V-8 Models - While holding one nut with an
open-endwrench, tighten the secondadjusting nut to
100-120ft. Ibs. (136-163N-m).
2972
i
10
2953
Engin~en9 10-7
Exhaust Hose Attachment
El 3.0 Mode|s - Slide exhaust hose (~ up onto high-rise exhaust

elbow ®.
V-6 and V-8 Models - Pushlower hoses (~) up onto intermedi-

ate exhaust pipes (~.
E~ Position and tighten all hose clamps securely between ribs

of exhaust hose(s) as shown.
E~ ~ Do NOT install hose clamps in expanded area (~ of 2945

hose(s)= Cooling will be restricted and engine damage
will occur.
Throttle Cable Installation
Move remote control handle to the NEUTRALdetent

position, Turn propeller shaft and shift into the forward gear
detent position, and then pull HALFWAY BACKtowards NEU-
TRAL.This positions the control for proper throttle cable adjust-
ment. Failure to follow this procedurecan bind the shift linkage in
the control, and produce hard shifting.
r~ 1. Align internal bosses ® of trunnion with throttle cable
17372A
groove (~). Press trunnion on throttle cable until seated.
Engine anchor bracket may have two sets of anchor block

holes. The top set is for the 4V (4 barrel) carburetor models, and
the bottom set is for the 2V (2 barrel) carburetor models.
E~ z~ 2. Install open end ~) of trunnion in anchor block. Install

screw in anchor block and position throttle cable assembly in
selected set of holes. Nut (~ mustbe against the anchorbracket,
tighten it securely.
[~ ~ 3. Throttle arm connector (~) must have a minimumof

full turns or 1/4 in. of throttle cable thread engagement, Instaim 17370A
throttle arm connector onto the throttle cable. Pull connector

forward (~) to removeall end pJay from throttle cable, then turn
the connector in until hole aligns with the throttle arm (~.
®
[~ If throttle arm connector hole cannot be adjusted to align
with the throttle arm, check for proper cable installation in the
remote control box.
34751
Safety Related 10-8

DR4978 DR4979 DR4980
[’~ ~ 4. Carburetor, Gi and GSi Models: Install connector onto

throttle arm. Install washerand cotter pin ©, andspreadcotter
pin prongs.Tighten jam nut ~) against connector.
DE] ~ 5. Fi and FSi Models:Install connectoronto throttle arm.

Install and tighten throttle armIocknut®. Tighten jam nut
against connector.
! Note l For throttle and shift cable adjustmentprocedures,see
Throttle andShift ControlSystems

section. 22698
WaterHoseinstallation
r.~ 1. Slide hoseclamp@onto water inlet hose. Lightly lubricate

inside of water inlet hoseandpushhoseonto water inlet tube ®.
[~ 2. If inlet hoseis not installed properly, undersideof hosemay

collapse. Checkundersideof hosefor properinstallation s:nd ad-
just hoseas required. Tighten hoseclampsecurely.
N°te=iFailure to install waterinlet hosecorrectly canresult in en- 15864
gine damage from blockageof water circulation.
PowerSteeringLine installation
1. Remove tape or protective cover from small hydraulic hosefit-

ting (or unscrewsteering line connector)andsmall steering cylin-
der opening.
[1~ 2. Install smat/Ihosefitting into steeringcylinder andtighten to
10-12ft. Ibs. (14-16N.m).
22702
3. Removetape or protective coverfrom large hydraulic hosefitting
andlarge steering cylinder opening.
L~4. Install large hosefitting into steering cylinder andtighten to

15-17ft. Ibs. (20-2!3N.m).
12
s~i.~o,~ ~ Safety Related 10-9 22701
24208 33730
Electrical Cable Connections
[’~ 1. Connectplastic two-wire plug of engineharnessto two-wire

receptacle@of trim/tilt motor. Connectorsshouldlock together.
[~] 2. Connectrubber two-wire trim/tilt senderplug to two-wire

receptacle ® of instrument harness. Secureconnectorswith wire
retainer andcable with a tie strap @.
3. Routethe instrumentcable plug to join enginecable receptacle 33727

on engine.
L~ Ensurecable is routed to prevent cutting or chafing on any

sharpor hot object. This couldresult in an electrical short, andcon-
tribute to fire andexplosionin the enginecompartment.
EEl4. Carburetor, Gi, and GSi Models:Routetrim/tilt cable be-

hind shift bracketandinstall plug @into electrical bracket.
5. Apply a light coat of Volvo PentaGreasearoundlarge en-

gine plug(~). 29790
DE] 6. Align the marksof the trim/tilt plug and receptacle F

and press together.
¯ Carburetor, Gi and GSi Models [~
¯ Fi and FSi Models E~
E~ [~ 7. Slide hose clamp over large engine receptacle. Align

the two large terminals on plug and receptacle @and press to-
gether. Slide hoseclampover receptacle and tighten securely.
3146O
¯ Carburetor, Gi and GSi Models [~
- Fi and FSi Models [~]
~8. Modelswith Starter Solenoids:Position the red cable pro-

tector over solenoidterminal.
9. Makecable connectionsat the battery. Be sure polarity is ob-

served;positive (+) cable to the positive terminal, andnegative(-)
cable to the negativeterminal.
Safety Related 10-10

Fuel Supply Connection
Attach boat’s fuel supply hose to fuel filter canister. Tighten

connectionsecurely, Checkfor fuel leaks whentesting engine,
and repair any leaks that might occur.
Rear Engine Mounts
Removal
1~. Removeengine as previously described in this section.

6678
2. Unscrewtwo screws and washers, then lift mount assem-

bly off transomplate.
Disassembly
[~] Hold square nut and remove screw. Mount assembly will
break down into componentsshown. Pay particular attention to
the two mount washers; their thickness, their shape (concave or
fiat) and their position in the assembly(above or below the rubber
mount).
Assembly 16348
L’~ 1. Slide lower washer ® onto mount bolt; make sure you
choose the correct washer (as determined during the mount
disassembly)for this position, insert bolt into bottom (flat) side
rubber mount assembly, and install remaining washer and
square nut. Do not tighten nut at this time.
If top and bottom washersare not installed in their original

positions, mount may transmit excessive engine vibrations into
boat and cause undesirable operating conditions.
[~ 2. Turn mount assembly upside down and clamp square nut 6680
in vise. Rotate rubber mountuntil mounting holes are posil:ioned
at 90° to any side .of square nut. Hold mountin this position and
tighten center bolt to 44-52 ft. Ibs. (60-71 N-m).
if 900 relationship between nut and mounting holes is not

maintained, slot of engine mount pad cannot engage rear mount
during installation.
Installation
D"~ 1. Place mount assembly on transom plate, install two
screws and washers, and tighten them to 20-25 ft. Ibs. [27-34
6677
N-m).
2. Install engine as previously described in this section.

Makesure mount pad slot engagessquare nut. install both fiat
washers and lock nuts, then tighten lock nuts to 28-30 ft. Ibs.
(38-41 N.m).
®
©
DR4960
Determining MinimumEngine Height

r~ 1. To determine minimumengine height, use a level ~)
placed on top of the transom,measurefrom bottomof level to top
of elbow ® and record distance.
2. Measurefrom bottomof level to static water line © and

record distance.
I~ 3. Subtract dimension (~ from dimension © and record

result. Seeengine height requirementsbelow:
® 3.0 Models - Measurement© minus @should not be

less than 9 in. (22,8 cm).
e V-6 Models - Measurement© minus ® should not be
less than 13 in. (33 cm).
¯ V-8 Models - Measurement© minus (~) should not
less than 14 in. (35,6 cm).
4. Whenengineinstallations do not meetthese specifications, an
exhaustelbowhigh-rise kit mustbe installed.
An installation that permits water to enter the engine

through the exhaustmanifolds(s) will not be coveredby warran-
ty, unlessdamage is dueto defective part(s).
Safety Section
Part A
Marine Products and Safety of People Who Use Them . . . . . . . . . S-2
Sterndrive Shift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3
Sterndrive Throttle Control System . . . . . . . . . . . . . . . . . . . . . . . . S-4
Sterndrive Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5
Sterndrive Fuel, Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . S-7
Part B
Marine Products and Safety of People Who Fix Them . . . . . . . . S-11
Handling Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-11
Handling Lead Acid Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-12
Gasoline! Handle with Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13
Hazardous Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-14
Safety
S-1
Part A - Marine Products and safety of
People Who Use Them
Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufacturers are
careful to make sure...
Product User is informed. . .
Products are safe and reliable. . .
It's up to you, the People who. . .
Install accessories. . .
Service and Maintain the boat. . .

Service and maintain the sterndrive. . .
. . . to keep the products safe and reliable.
This section talks about safe boating and how you can help keep it safe. Some things you may know
. . . but others you may not.
First!
A word about fasteners . . . plain . . . special . . . all screws, nuts, washers and bolts.
Do Not Substitute Fasteners
They look the same, but . . . are they?
The Same Size?

The Same Strength?
The Same Material?
The Same Type?
Standard or Metric Thread?
Don't substitute unless you know they are the same in all characteristics.
Second!
Special locking screws and nuts are often used to attach steering, and remote control components to
the sterndrive.
When you remove any part from the sterndrive, keep track of special screws and nuts. Don't mix with
other parts
When reassembling the sterndrive, use only the special screws and nuts intended to hold steering, and
control cables, plus related parts.
Service with parts of known quality that meet Marine Industry (BIA/ABYC) Standard.
S-2 Safety
Sterndrive Shift System
The Shift System starts

here at the remote control lever. . .
. . . and ends here at the propeller.
What's Most Important?
When the control lever is in Forward,

Neutral or Reverse position . .
. . . Shift mechanism must match

control lever position.
What Could Happen?
If . . . Neutral If . . . Forward
Forward
or
Reverse
Reverse
. . . Propeller is still powered (turning) . . . boat will move opposite

unknown to operator, or engine will to direction intended by operator.
start in gear, boat will move unexpectedly.
How Can Loss of Shift Control be Minimized? In pre-delivery inspection and when servicing . . .
Read, understand and follow manufacturers instructions.
Closely follow the warnings marked with ...
Assemble parts and make adjustments carefully . . .
Test your work. Don't guess. Make sure propeller does what the operator wants and
nothing else.
Safety
S-3
Sterndrive Throttle Control System
The throttle Control System starts

here and the remote control lever . . .
. . . and ends
here on the engine.
When the control lever is moved from

Forward (or Reverse) to Neutral . . .
. . . engine speed must slow to idle
RPM and allow operator to shift into
Neutral.
Operator must be able to stop propeller.
What Could Happen?
If operator cannot slow the engine to idle RPM and shift into neutral, (stop propeller), operator could panic and lose control
of boat.
How Can Loss of Throttle Control be Minimized? In pre-delivery inspection and when servicing . . .
Read, understand, and follow manufacturers instructions.
Assemble parts and make adjustments carefully . . .
Test your work. Don't guess. Make sure engine throttle response is smooth.
Make sure full throttle operating RPM can be reached so operator won't overload engine
S-4 Safety
Sterndrive Steering System
The Steering System starts

here at the helm . . .
The Steering System . . .

. . . and ends here at the propeller
on the sterndrive
must be installed properly
must be adjusted properly
must be lubricated
What Could Happen?
. . . if steering system comes apart, boat would turn suddenly and circle . . . passengers and/or operator
may be thrown into water and could be hit.
. . . if steering jams, operator may not be able to avoid obstacles. Operator could panic.
. . . if steering is loose, operator may not be able to maintain a true course, and could result in loss of
boat control.
Safety
S-5
How Can Loss of Steering Control be Minimized?
In pre-
use steering components which meet marine industry (BIA/ABYC) standards . . .
delivery Read, understand, and follow manufacturer's instructions.
inspection Assemble parts and make adjustments carefully . . .
and when Closely follow the warnings marked with ...
servicing Keep parts moving freely . . . lubricate parts as soon as shown in manuals
Use bolts, nuts, and washers supplied with steering attachment kits
When power assisted or mechanical steering systems are used, check to uncover possible trouble!
Cable housing in this area

must not be restricted Steering components must not
bind
Why? Unit may go to full turn without
Why? Possible jamming of steering
turning steering wheel (Power
system.
assist models)
Engine stringer must not interfere

with power steering pump and pul-
ley
Maintain proper belt tension.
Power steering parts and push/pull cable

must be free to move in order to actuate
power steering valve when operator
turns steering wheel
Check for damaged parts . . . impacts to the sterndrive like this
or this . . . or ? ? ?
can put stress on steering components. Look for . . .
Cracked parts
Bent parts
Loose fasteners
Replace damaged parts. If weakened, parts could fail later . . . on the water
. . . when least expected.
S-6 Safety
Sterndrive Fuel and Electrical Systems
The electrical System begins

here at the battery . . .
. . . and ends here
at the carburetor or fuel injectors
The fuel system

starts here at the fuel tank . . . . . . and ends
here on the en-
gine.
What's Important?
Fuel leakage must be prevented.

Electric sparks must not happen.
What Could Happen?
Gasoline can explode and/ or burn easily:
When boating, fuel leaking in the engine compartment could be ignited by a spark from a loose wire
connection, or a damaged or deteriorated electrical component.
How Can Fire and Explosion Be Minimized?
Read, understand and follow manufacturers instructions.
Do not substitute fuel or electrical parts with other parts which may look the same. These parts are
designed and manufactured to meet special U. S. Coast Guard safety regulations to prevent fire and
explosion.
If you work on marine engines, you must understand these U.S. Coast Guard requirements. If you don't have them, write
to . . .
---------
---------
---------
National Technical Information Service
Springfield, Virginia 22161
. . . and ask for copies of:
(1) Electrical System Compliance Guideline (AD/A-049-638)

(2) Fuel System Compliance Guideline (AD/A-047-767)
These are concise guidelines - easy to read and understand. They explain what must be done to prevent fire and explo-
sions.
Safety
S-7
Always use replacement parts specified by the manufacturer. They meet the U.S. Coast Guard require-
ments. Most automotive parts do not, especially electrical components that must meet ignition protec-
tion requirements of the U.S. Coast Guard regulations.
When nonmetallic parts look to be in poor shape . . . replace them!
Torn Boots!
Wires Cracked!
Cracked Fuel Lines!
Using parts which meet U.S. Coast guard requirements is only half the job. The other half is your job . . .
It's time for replacement BEFORE sparks and/or fuel leaks occur.
Replace parts carefully. Make sure nuts and bolts are tight especially when they anchor electrical wires
(to prevent sparking). If lock washers are specified - use them. No short cuts or missing parts with
either of these CRITICAL safety related systems.
When refueling, always ground fuel nozzle to the inlet fitting on the boat to prevent the buildup of
electrostatic sparks. If you use a funnel, make sure it's metal and ground the fuel nozzle to the funnel.
If you smell gasoline in the engine compartment . . .

STOP find its source and stop the leakage.
S-8 Safety
Follow "Starting Procedure" outlined in the operator's manual.
Always make sure there are no gasoline fumes in the engine compartment before starting the
engine. Open the compartment and use your nose. Don't gamble.
Backfire flame arrestor must be in place and securely attached to the air intake.
Do not alter the backfire flame arrestor.
If loose, damaged, or altered, an engine "backfire" may pass through the flame arrestor assembly into the engine compart-
ment. If fumes are present in compartment, fire and explosion could result.
Safety
S-9
Summing Up
Now you know some things that can take the joy out of enjoyable boating.
No doubt about it . . . it takes time!
Reading and understanding instructions.
Reading and understanding warnings marked with ...
Putting parts together correctly . . .
Making correct adjustments . . .
Testing you work.
and making sure
Worn or damaged parts are replaced,
Replaced parts are like originals . . . in every way.
Customer is told of things which need attention . . .
But do you really want the alternative?
S-10 Safety
Part B - Marine Products and Safety of
People* Who Fix Them
Part A talked about safe boating and how you, the mechanic, can help keep it safe for the boater. But what about you?
Mechanics can be hurt while . . .
Servicing boats
Servicing sterndrives
Troubleshooting problems
Testing their work
Some items you'll know . . . others you may not.
When Lifting Engines
If hoist is poor shape . . . or too small for the job
Engine may drop suddenly
DR3471 DR3469
Make sure shop aids have extra capacity — and keep them in good repair!
When Running Engine with Engine Compartment Cover Removed
The engine compartment cover is a guard. When you remove the cover / guard to work on the engine, remember:
Loose clothing (open shirt sleeves, neckties), long hair, jewelry (rings, watches, bracelets), hands,
arms, belts can be caught by moving belts or spinning pulleys
Handle high voltage ignition components carefully. They can shock you and may cause you to recoil into
moving parts.
Two people working together on a running engine must look out for each other. Never, ever, hit the key to start the
engine before signalling to your partner. (He may be leaning over the engine with his hands on a belt, or a "hot" electri-
cal part, near the propeller, etc.)
*Mechanics, technicians, backyard do-it-yourselfers.
Safety
S-11
Exhaust gasses of running engines contain carbon monoxide. . . you can't see it. . . you can't smell it. . .
you can't taste it. . . but it's there whenever an engine runs. . . and it's deadly!
When you smell the other gasses in the exhaust, you are inhaling carbon monoxide. Run engines only in well ventilated
areas.
Eyes Need help
Grinding Sprayed
Cleaners,
Paints
End of Cables Acid
Chiseling
(steel on steel)
(Tip: Use plastic or brass type hammers.
They don't chip off as easily as steel hammers.)
Handling Lead Acid Batteries
If spilled or splashed on
any part of body..
Wash with lots

If solution gets
of water. . .
into eyes. . .
Wash. . . and see a Doctor, fast!
Charging Lead Acid Batteries
Attach and remove these cables

with charger unplugged from 110 volt wall
socket. (Prevents shocks if the charger
is defective.)
Observe correct polarity when con-

necting these charger leads.
Always charge in a well ventilated

area. Charging causes acid solution to
give off hydrogen gas through the vents
in the caps. . . Make sure vents are open.
If clogged, pressure inside may build. . .
battery may explode.
S-12 Safety
Never yank cables off
Battery gas is explosive! battery posts. . . it's a sure
While charging or discharging, way to make lots of
remember. . . sparks. . .surrounded by battery gas
No Smoking
No Flames
No Sparks
Don't check battery condition After Charging. . .

by placing metal objects
across posts. Shut off charger
You're sure to make sparks Remove charger plug from wall socket
Then. . .
and serious burns are
possible. Take charger cable off battery posts
Gasoline! Handle With Care

When you smell any odor of gasoline,
explosion is possible
Gasoline fumes are heavier than air and will sink

to the lowest point in the boat or room,
and will stay there. . . waiting
Gasoline explodes easily and violently when

If the air around you is quiet . . . the pilot light in mixed with air
the heater may
ignite the heavy fumes 5 Parts
before your nose ever Gasoline
smells the fumes . .
100 Parts
Air
What Can you Do?
Store properly . . .
Fill portable tanks outside boat to prevent spillage in
boat
Use fuel for fuel . . . not for a solvent
If fumes are smelled (in shop, basement, garage), immediately:
Store in sturdy, Put out open flames, cigarettes, sparking devices
sealed gas can Wipe up spill or leak; get towels, rags outside fast
. . .and . . . Check lowest area for fumes; open doors or win-
keep outside dows
Safety
S-13
Know items in and around repair area which can ignite gasoline fumes . . . Control them if fumes are smelled.
Matches, cigarettes, torches, welders

Electric motors (with unsealed cases)
Electric generators (with unsealed cases)
Light switches
Appliance pilot lights (furnace, dryer, water heater)
?????????
How many of these are in your area?
Hazardous Products
Read the container label. It tells you . . .
"How, and where, to use,"

"How to give First Aid," and have "recommended" first aid materials on hand- should an
emergency arise
"How to dispose of can,"
Remember: Little children are very curious and will try to taste everything, so . . .
. . . yummmmmmmmmmm Keep containers away

from children
S-14 Safety
VOLVO PENTA MODEL iDENTiFiCATiON
Engine Modelidentification 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)
modulebracket for Ford fuel injection models. The identification numbersmust correspond with
the transom shield and drive unit numbers. See below.
Engine Model Number(GL, GS, and Gi Models)
Engine Model Number(Fi Models)
SX MODELS:
[~ Transom Shield Model Number
[~ Drive Unit Model Number
DP & DPX MODELS:
Nunber plate for drive unit andtransomshield.

Onlyfields 2 and3 arefilled for transomshield.
1 4
3
1. ProductDesignation
2. Model Number
3. Serial Number
4. ReductionRatio

NC Engine Manual

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

NC Engine Manual

Hochgeladen von

Copyright:

Verfügbare Formate

Safety Warning

This WorkshopManual will alert you to certain procedures that

® injure yourself or people around you

Understand the following symbols before proceeding:

Alerts you to the possibility of dangerand

Appearsnext to information that controns

This WorkshopManual is written for qualified, factory trained

This Workshop Manual reins you how to correctly maintain and

WhenVolvo Penta special toots are called for, use them.

if you use service proceduresor service tools that are not

General information ....................

4.3, 5.7 Engines

5.0, 5.8 FL Engines ....................

5.0, 5.8 Fi Engines

7.4, 8.2 Engines

Engine Removal and Installation ...........

© 1996 Volvo Penta of the Americas, Inc. All Rights Reserved

¯ P/N 7788881-6SX, DP-SDHveUnit and Transom

¯ P/N 77888824MRDiagnostic(5.0 F~ 5.8 Fi/FSi). Ford

¯P/N 7788885.7SP-DPDrive Unit and TransomShield

¯ PiN 7788888-1Fuel System

, PiN 7788889=9DPX-LowerUnit and )(act TM Steering System

Service required for Volvo Penta stern drives is generally one of

® Normalcare and maintenance-which includes putting a

@ Operating ma|functions - due to improper engine or

e Complete disassembly and overhaul - such as major

It is important to determine before disassembly just whal the

Whenrepairing an assembly, the most reliable way to ensure a

Repair time can also be minimized by the use of special tools.

Do not operate engine out of water even momentarily. If

Proper preparation is extremely helpful for efficient service work.

Z/~ Use proper lifting and handling equipment. Working on stern

AJwaysuse clean fresh fuel when testing engines. Troubles can

Whetherwithin or fonlowing the warranty period, Volvo Penta has

it is Volvo Penta’a policy to provide dealers with service knowl-

Whena brand-nameproduct or specific too[ is called for, another

Whenreplacementparts are required, always use genuine

Z~ Parts Catalogsare a goodsourceof information for ordering

Fa#ureto follow wodrshopmanualproceduresand

Special Service Tools

VolvoPentahas specially designedtools to simpJify disassembly

Safety Re|ated 1-4 Engineleng

Er,~=,~ng ~ Safety Related 1-5

¯ 3.0GS, 4.3GL, GS, 4.3, 5.7, 7.4, 8.2Gi, andGSi

Theindicated compression pressuresare considerednormalif the nowest

If the highestpressurereadingwas140PSI, 75%of 140is 105. Therefore,

If oneor morecylinders readlow, squirt approximately onetablespoonof

3. ff twoadjacentcylindersindicate low compressionpressuresandsquirt-

SafetyReJated 1-6 Engine/eng

CompressionPressure Limit Chart

Max. Min. Max. Min. Max. Min. Max. Min.

134 101 154 115 174 131 194 145

After checking cylinder compression, repairs should be madeas

¯ Spark Plugs ¯ Fuel Tank Pickup and Screen

All of the abovelisted componentsare not necessarily part of an

Z~ Do not substitute automotive parts. Volvo Penta marine

Eng~..;o.~ L~ Safety Related 1-7

Volvo Penta engines are designed for maximum performanceus-

¯ Anti-knock Index Number(AKI) -

4.3 GL, GSModels: Theignition timing mustbe retarded if fuels

,~ Use of gasoline with lower than 89AKI (93 RON)octane

Fuel injected Models:Every attempt should be madeto use un-

CarburetedModels:Useof lead-free or leaded gasoline is ac-