Volvo Penta Stern Drive 5.7 GL/SX (1994 - 2000) Clymer

This Volvo Penta marine manual is 848 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specifications

CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanicâ??s techniques / Specifications

CHAPTER THREE / TROUBLESHOOTING
Starting system / Charging system / Ignition system / Fuel system (carbureted models) / Fuel system (fuel injected 4.3 L, 5.0 L and 5.7 L engines) / Fuel system (fuel injected 5.0 L and 5.8 L engines) / Fuel system (fuel injected 7.4 L engines) / Engine performance / Engine overheating / Engine oil pressure / Engine oil leaks / Engine noises / Stern drive unit / Specifications

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-operational checks / Starting checklist / Post-operational checks / Cooling flushing / Cooling system draining / Engine maintenance and lubrication / Engine oil and filter change / Fuel system service / Fuel filter service / Fuel quality / Flame arrestor service / Battery service / Drive belt condition and tension / Steering system service / Power trim and tilt service (SX models) / Power trim and tilt system service (DP and DPX models) / Stern drive lubrication / Stern drive lubricant change / Gimbal bearing, driveshaft splines and universal joint lubrication (SX models) / Steering and tilt bearings, drive shaft and universal joints (DP and DPX models) / Zinc anode check and replacement / Engine tune-up / Compression check / Valve clearance / Ignition system / Spark plugs / Sensor air gap (BID models) / Ignition timing / Carburetor service / Idle speed and mixture / Specifications

CHAPTER FIVE / LAY-UP, COOLING SYSTEM SERVICE AND FITTING OUT
Lay up / Cooling system draining / Filling closed cooling system / Fitting out / Specifications

CHAPTER SIX / 3.0 LITER 4-CYLINDER ENGINES
Removal installation / Rocker arm cover / Intake exhaust manifold / Exhaust bellows and flapper valve / Rocker arm assemblies / Crankshaft pulley, harmonic balancer and hub / Timing gear cover and seal / Camshaft / Oil pan pump / Cylinder head / Valves and seats / Valve lifters / Piston / connecting rod assembly / Rear main oil seal / Crankshaft / Diver coupler and flywheel / Cylinder block / Core plug / Specifications

CHAPTER SEVEN / 4.3 LITER V6; 5.0, 5.7, 7.4 AND 8.2 LITER V8 ENGINES
Removal installation / Valve covers / Manifold / Exhaust bellows and flapper valve / Rocker arms / Crankshaft pulley and harmonic balancer / Timing chain front cover and oil seal / Timing chain and sprockets / Balance shaft / Camshaft / Oil pan pump / Cylinder head / Valves and seats / Valve lifters / Piston / connecting rod assembly / Rear main oil seal / Crankshaft / Drive coupler and flywheel / Cylinder block / Core plug / Specifications

CHAPTER EIGHT / 5.0 LITER AND 5.8 LITER V8 ENGINES
Removal installation / Valve covers / Intake manifold / Manifolds / Exhaust bellows and flapper valve / Crankshaft pulley and vibration damper / Front cover and seal / Timing chain and sprockets / Rocker arm assemblies / Camshaft / Oil pan pump / Cylinder head / Valves and seats / Valve lifters / Piston / connecting rod assembly / Rear main oil seal / Crankshaft / Drive coupler and flywheel / Cylinder block / Core plug / Specifications

CHAPTER NINE / FUEL DELIVERY SYSTEMS
Flame arrestor / Carburetors / Fuel injection systems / Troubleshooting / Multipoint fuel injection / Specifications

CHAPTER TEN / COOLING SYSTEM
Thermostat / Engine circulating pump / Seawater pump / Drive belts / Closed cooling system maintenance / Standard cooling system maintenance / Oil cooler / Specifications

CHAPTER ELEVEN / ELECTRICAL SYSTEMS
Charging system / Starting system / Ignition system / EST ignition / BID ignition / TFI-IV ignition / Ignition coil / Switches and connectors / Solenoids / Electrical protection / Specifications

CHAPTER TWELVE / DRIVE UNIT AND UPPER GEARCASE
Drive unit gear ratio / High altitude operation / Corrosion control / Drive unit lubrication / Drive unit removal installation / Universal joint / Upper gearcase service / Shift housing service / Specifications

CHAPTER THIRTEEN / LOWER GEARCASE
Lower gearcase operation / Corrosion control / Propellers / Lower gearcase service / Specifications

CHAPTER FOURTEEN / INTERMEDIATE HOUSING AND TRANSOM SHIELD (BRACKET)
Intermediate housing (DP-C1 / D1 and DPX models) / Transom shield (DP-C1 / D1 and DPX models) / Transom bracket (SX and DP-S models) / Specifications

CHAPTER FIFTEEN / POWER TRIM AND TILT SYSTEMS
Specifications

CHAPTER SIXTEEN / STEERING SYSTEMS
Mechanical steering system / Power steering system / Specifications

CHAPTER SEVENTEEN / SUPPLEMENT 1998-2000 MODELS

INDEX

WIRING DIAGRAMS

Models covered:
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 3.0 GL/SX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 3.0 GS/SX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 4.3 GL/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 4.3 GL/SX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 4.3 GS/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 4.3 GS/SX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 4.3 Gi/SX/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.0 FL/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.0 FL/SX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.0 Fi/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.0 Fi/SX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.0 GL/SX/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.0 Gi/SX/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.7 GL/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.7 GL/SX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.7 GS/SX/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.7 GSi/SX/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.7 Gi/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.7 Gi/SX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.8 FL/SX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.8 FSi/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.8 FSi/SX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.8 Fi/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 5.8 Fi/SX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 7.4 GL/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 7.4 GSi/DPX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 7.4 Gi/SX/DP
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 8.2 DPX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 8.2 GL/DPX
1994 1995 1996 1997 1998 1999 2000 Volvo Penta 8.2 GSi/DPX

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Volvo Penta 3.0 GL/SX (1994-2000)
Volvo Penta 3.0 GS/SX (1994-2000)
Volvo Penta 4.3 GL/DP (1994-2000)
Volvo Penta 4.3 GL/SX (1994-2000)
Volvo Penta 4.3 GS/DP (1994-2000)
Volvo Penta 4.3 GS/SX (1994-2000)
Volvo Penta 4.3 Gi/SX/DP (1994-2000)
Volvo Penta 5.0 FL/DP (1994-2000)
Volvo Penta 5.0 FL/SX (1994-2000)
Volvo Penta 5.0 Fi/DP (1994-2000)
Volvo Penta 5.0 Fi/SX (1994-2000)
Volvo Penta 5.0 GL/SX/DP (1994-2000)
Volvo Penta 5.0 Gi/SX/DP (1994-2000)
Volvo Penta 5.7 GL/DP (1994-2000)
Volvo Penta 5.7 GL/SX (1994-2000)
Volvo Penta 5.7 GS/SX/DP (1994-2000)
Volvo Penta 5.7 GSi/SX/DP (1994-2000)
Volvo Penta 5.7 Gi/DP (1994-2000)
Volvo Penta 5.7 Gi/SX (1994-2000)
Volvo Penta 5.8 FL/SX (1994-2000)
Volvo Penta 5.8 FSi/DP (1994-2000)
Volvo Penta 5.8 FSi/SX (1994-2000)
Volvo Penta 5.8 Fi/DP (1994-2000)
Volvo Penta 5.8 Fi/SX (1994-2000)
Volvo Penta 7.4 GL/DP (1994-2000)
Volvo Penta 7.4 GSi/DPX (1994-2000)
Volvo Penta 7.4 Gi/SX/DP (1994-2000)
Volvo Penta 8.2 DPX (1994-2000)
Volvo Penta 8.2 GL/DPX (1994-2000)
Volvo Penta 8.2 GSi/DPX (1994-2000)