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Volvo Penta Stern Drive 81GI, 8.1L V-8 (375 HP) (2001 - 2004)

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The original Haynes Repair Manual - Based on a complete stripdown and rebuild of a vehicle

Volvo Penta Stern Drive 81GI, 8.1L V-8 (375 HP) (2001 - 2004)

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This Volvo Penta marine manual is 688 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Model identification / Engine operation / Fasteners / Shop supplies / Galvanic corrosion / Propellers / Basic tools / Special tools / Precision measuring tools / Electrical component replacement / Electrical system fundamentals / Basic mechanical skills / Specifications

CHAPTER TWO / TROUBLESHOOTING
Electrical component replacement / Preliminary inspection / Electric starting system / Charging system / Ignition system / Basic fuel system troubleshooting / Carburetor fuel system / Electronic fuel injection (EFI) system / Diagnostic trouble codes / Power steering system / Power trim electrical system troubleshooting / Power trim hydraulic system troubleshooting / Cooling system troubleshooting / Warning system / Engine troubleshooting / Drive system / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Before each use / After each use / Lubrication / Engine oil and filter change / Drive unit lubricant change / Steering cable lubrication / Gimbal bearing lubrication / Engine coupling lubrication / Engine alignment check / Fuel system maintenance / Fuel requirements / Water-separating fuel filter service / Flame arrestor cleaning / PCV valve cleaning / Engine coolant / Tune-up / Compression test / Spark plugs / Carburetor adjustments / Ignition timing adjustment / Test running the engine / Submersion / Specifications

CHAPTER FOUR / LAY-UP, WINTERIZING AND FITTING OUT
Lay-up / Winterizing / Fitting out / Specifications

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 43GL, 4.3 L V-6 (160 HP)
2001 2002 2003 2004 Volvo Penta 43GI, 4.3 L V-6 (180 HP)
2001 2002 2003 2004 Volvo Penta 43GXI, 4.3 L V-6 (210 HP)
2001 2002 2003 2004 Volvo Penta 50GL, 5.0 L V-8 (220 HP)
2001 2002 2003 2004 Volvo Penta 50GI, 5.0 L V-8 (250 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)

Clymer Manuals Volvo Penta 30GS, 3.0 L in-line 4-cyl (135 HP) Manual
Clymer Manuals Volvo Penta 43GL, 4.3 L V-6 (160 HP) Manual
Clymer Manuals Volvo Penta 43GI, 4.3 L V-6 (180 HP) Manual
Clymer Manuals Volvo Penta 43GXI, 4.3 L V-6 (210 HP) Manual
Clymer Manuals Volvo Penta 50GL, 5.0 L V-8 (220 HP) Manual
Clymer Manuals Volvo Penta 50GI, 5.0 L V-8 (250 HP) Manual
Clymer Manuals Volvo Penta 50GXI, 5.0 L V-8 (270 HP) Manual
Clymer Manuals Volvo Penta 57GS, 5.7 L V-8 (225 HP) Manual
Clymer Manuals Volvo Penta 57GS, 5.7 L V-8 (250 HP) Manual
Clymer Manuals Volvo Penta 57GSI, 5.7 L V-8 (280 HP) Manual
Clymer Manuals Volvo Penta 57GXI, 5.7 L V-8 (320 HP) Manual
Clymer Manuals Volvo Penta 81GI, 8.1 L V-8 (375 HP) Manual
Clymer Manuals Volvo Penta 81GXI, 8.1 L V-8 (420 HP) Manual
Clymer Manuals Volvo Penta DPX375, 8.1 L V-8 (375 HP) Manual
Clymer Manuals Volvo Penta DPX420, 8.1 L V-8 (420 HP) Manual
Clymer Manuals Volvo Penta 30GS, 3.0 L in-line 4-cyl (135 HP) Online Manual
Clymer Manuals Volvo Penta 43GL, 4.3 L V-6 (160 HP) Online Manual
Clymer Manuals Volvo Penta 43GI, 4.3 L V-6 (180 HP) Online Manual
Clymer Manuals Volvo Penta 43GXI, 4.3 L V-6 (210 HP) Online Manual
Clymer Manuals Volvo Penta 50GL, 5.0 L V-8 (220 HP) Online Manual
Clymer Manuals Volvo Penta 50GI, 5.0 L V-8 (250 HP) Online Manual
Clymer Manuals Volvo Penta 50GXI, 5.0 L V-8 (270 HP) Online Manual
Clymer Manuals Volvo Penta 57GS, 5.7 L V-8 (225 HP) Online Manual
Clymer Manuals Volvo Penta 57GS, 5.7 L V-8 (250 HP) Online Manual
Clymer Manuals Volvo Penta 57GSI, 5.7 L V-8 (280 HP) Online Manual
Clymer Manuals Volvo Penta 57GXI, 5.7 L V-8 (320 HP) Online Manual
Clymer Manuals Volvo Penta 81GI, 8.1 L V-8 (375 HP) Online Manual
Clymer Manuals Volvo Penta 81GXI, 8.1 L V-8 (420 HP) Online Manual
Clymer Manuals Volvo Penta DPX375, 8.1 L V-8 (375 HP) Online Manual
Clymer Manuals Volvo Penta DPX420, 8.1 L V-8 (420 HP) Online Manual

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

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