Volvo Penta Stern Drives, 2001-2004
Part #: B775

688 pages

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION

CHAPTER TWO / TROUBLESHOOTING

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP

CHAPTER FOUR / LAY-UP, WINTERIZING AND FITTING OUT

CHAPTER FIVE / ADJUSTMENTS
Carburetor / Ignition timing / Shift cable and linkage / Throttle cable / Trim position sender and trim limit control module / Specifications

CHAPTER SIX / ENGINE
Removal installation / Engine alignment / Rocker arm cover / Valve adjustment / Placing the No. 1 piston at TDC / Lifter cover / Camshaft lobe lift measurement / Cylinder head / Rocker arm and pushrod / Flywheel housing / Drive coupler / Drive plate / Flywheel / Flywheel pilot bearing / Output drive shaft, seals and bearings / Oil pan pump / Harmonic balancer / Timing gear/chain cover / Timing chain and sprockets / Balance shaft / Camshaft and lifters / Piston and connecting rod / Rear main seal and rear main seal carrier / Crankshaft / Break-in procedure / Specifications

CHAPTER SEVEN / FUEL SYSTEMS
Fuel system service / Mechanical fuel pump / Low-pressure electric fuel pump / Carburetor / Electronic fuel injection (EFI) / Intake manifold / Specifications

CHAPTER EIGHT / COOLING AND EXHAUST SYSTEMS
Thermostat / Recirculation pump / Seawater pump / Oil and power steering fluid cooler / Exhaust elbow / Exhaust bellow and flapper valve / Exhaust tube and flapper valve / Exhaust manifold / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Battery / Alternator / Starter motor and solenoid / Starter relay / Fuel pump relay / EFI system relay / Ignition system / Oil pressure sender / Oil pressure switch / Engine temperature sender / Engine temperature sensor / Engine overheat switch / Exhaust overheat switch / Intake air temperature sensor IAT / Throttle position sensor TPS / Idle air control motor IAC / Knock sensor / Knock sensor module / Engine control unit ECU / Warning horn replacement / Specifications

CHAPTER TEN / DRIVE UNIT
Drive unit service precautions / Drive unit identification / Drive unit operation / Drive unit gear ratio / High altitude operation / Outdrive service precautions / Sacrificial anodes / Shifting and propeller rotation / Propeller / Drive unit removal and installation / Upper drive shaft housing / Universal joint / Shift housing service / Pressure and vacuum test / Specifications

CHAPTER ELEVEN / INTERMEDIATE HOUSING AND TRANSOM SHIELD/BRACKET
Intermediate housing operation and inspection / Intermediate housing and suspension fork / Transom shield and mounting collar / Transom bracket / Specifications

CHAPTER TWELVE / POWER TRIM SYSTEM
Trim relay / Trim switch fuse / Trim limit control module / Trim motor / Trim pump / Fluid reservoir / Fluid screen / Hydraulic pump / Relief valve / Trim cylinder / Trim hose / Trim position sender / Filling and bleeding the trim system / Specifications

CHAPTER THIRTEEN / STEERING SYSTEM
Safety precautions / Mechanical (manual) steering system / Power steering system / Specifications

INDEX

COLOR WIRING DIAGRAMS

Models covered:
2001 2002 2003 2004 VOLVO PENTA 30GS, 3.0 L in-line 4-cyl (135 HP)
2001 2002 2003 2004 VOLVO PENTA 43GI, 4.3 L V-6 (180 HP)
2001 2002 2003 2004 VOLVO PENTA 43GL, 4.3 L V-6 (160 HP)
2001 2002 2003 2004 VOLVO PENTA 43GXI, 4.3 L V-6 (210 HP)
2001 2002 2003 2004 VOLVO PENTA 50GI, 5.0 L V-8 (250 HP)
2001 2002 2003 2004 VOLVO PENTA 50GL, 5.0 L V-8 (220 HP)
2001 2002 2003 2004 VOLVO PENTA 50GXI, 5.0 L V-8 (270 HP)
2001 2002 2003 2004 VOLVO PENTA 57GS, 5.7 L V-8 (225 HP)
2001 2002 2003 2004 VOLVO PENTA 57GS, 5.7 L V-8 (250 HP)
2001 2002 2003 2004 VOLVO PENTA 57GSI, 5.7 L V-8 (280 HP)
2001 2002 2003 2004 VOLVO PENTA 57GXI, 5.7 L V-8 (320 HP)
2001 2002 2003 2004 VOLVO PENTA 81GI, 8.1 L V-8 (375 HP)
2001 2002 2003 2004 VOLVO PENTA 81GXI, 8.1 L V-8 (420 HP)
2001 2002 2003 2004 VOLVO PENTA DPX375, 8.1 L V-8 (375 HP)
2001 2002 2003 2004 VOLVO PENTA DPX420, 8.1 L V-8 (420 HP)

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