Volvo Penta 3.0GS-A-B-C 3.0GL-A-B-C Engine Workshop Manual 7743358 – PDF DOWNLOAD

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Volvo Penta 3.0GS-A-B-C 3.0GL-A-B-C Engine Workshop Manual 7743358 – PDF DOWNLOAD

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Volvo Penta 3.0GS-A-B-C 3.0GL-A-B-C Engine Workshop Manual 7743358 – PDF DOWNLOAD

Language : English
Pages : 176
Downloadable : Yes
File Type : PDF
Size: 7.52 MB

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Volvo Penta 3.0GS-A-B-C 3.0GL-A-B-C Engine Workshop Manual 7743358 – PDF DOWNLOAD

Good Service Practice Service required for stern drives is generally one of three kinds:
• Normal care and maintenance – which includes putting a new
stern drive into operation, storing engines, lubrication, and care
General Information
under special operating conditions such as salt water and cold
weather.
• Operating malfunctions – due to improper engine or drive
mounting, propeller condition or size, boat condition, or the malfunction
of some part of the engine. This includes engine servicing
procedures to keep the engine in prime operating condition.
• Complete disassembly and overhaul – such as major service
or rebuilding a unit.
It is important to determine before disassembly just what the trouble is
and how to correct it quickly, with minimum expense to the owner.
When repairing 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. Wear not readily apparent on other parts could
cause malfunction soon after the repair job. Repair kits and seal kits
contain all the parts needed to 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 special tools are designed to perform service procedures
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 some cases, the use of substitute tools can damage the part.

TABLE OF CONTENTS:

Volvo Penta 3.0GS-A-B-C 3.0GL-A-B-C Engine Workshop Manual 7743358 – PDF DOWNLOAD

7742218_cover.pdf………………………………………………………………. 0
Page 1…………………………………………………………………….. 1
Section 2A.pdf…………………………………………………………………. 0
Contents…………………………………………………………………… 32
………………………………………………………………………. 32
General Description ……………………………………………………. 33
Sensors and Voltage Signals ……………………………………………… 33
Engine Control Module (ECM) ……………………………………………… 34
ECM Function ………………………………………………………….. 34
Memory ……………………………………………………………….. 34
Speed Density System ……………………………………………………. 35
ECM Inputs / Sensor Descriptions …………………………………………. 35
Engine Coolant Temperature (ECT) Sensor ………………………………….. 37
Manifold Absolute Pressure (MAP) Sensor ………………………………….. 37
Knock Sensor (KS) System ………………………………………………… 38
ENGINE PROTECTION MODE …………………………………………………. 39
Fuel System ……………………………………………………………. 40
Modes Of Operation ……………………………………………………… 40
Fuel Supply Components ………………………………………………….. 41
Fuel Pump Electrical Circuit …………………………………………….. 41
Fuel Injectors …………………………………………………………. 42
Pressure Regulator Assembly ……………………………………………… 42
Fuel System Operation ………………………………………………….. 44
Ignition System ………………………………………………………… 45
Ignition Coil ………………………………………………………….. 46
Ignition Control (IC) Module …………………………………………….. 46
Pole Piece and Coil Assembly ……………………………………………. 46
Engine Control Module (ECM) …………………………………………….. 47
Ignition Timing ……………………………………………………….. 47
Section 3A.pdf…………………………………………………………………. 0
Contents…………………………………………………………………… 50
………………………………………………………………………. 50
General Information ……………………………………………………. 51
Engine Control Module (ECM) …………………………………………….. 51
Engine Coolant Temperature (ECT) Sensor …………………………………… 52
Manifold Absolute Pressure (MAP) Sensor …………………………………… 53
Throttle Position (TP) Sensor ……………………………………………. 54
Idle Air Control (IAC) Valve …………………………………………….. 55
Knock Sensor (KS) ………………………………………………………. 56
Fuel System Component Replacement ………………………………………… 57
Fuel Control Service ……………………………………………………. 57
Fuel Pressure Relief Procedure …………………………………………… 58
Throttle Body Injector (TBI) Unit ……………………………………….. 59
Fuel Meter Cover Assembly ……………………………………………….. 61
Fuel Injector ………………………………………………………….. 63
Fuel Cell ……………………………………………………………… 66
Circuit Breaker ……………………………………………………….. 68
Relay Replacement ………………………………………………………. 68
Relay Ohmmeter Tests …………………………………………………… 69
Troubleshooting Electric Pump(s) ………………………………………… 70
Pressure Testing Fuel System ……………………………………………. 70
Troubleshooting Boat Fuel System …………………………………………. 71
Vacuum Testing Fuel System ……………………………………………… 71
Engine Fuel System Troubleshooting ………………………………………. 72
Engine Will Start When Primed – Will Not Continue to Run ……………………. 72
Engine Hard Starting, Cold ………………………………………………. 72
Engine Hard Starting, Hot ……………………………………………….. 72
Engine Runs Rough, Low Speed …………………………………………….. 72
Engine Runs Rough, High Speed ……………………………………………. 72
Engine Dies (On Initial Acceleration) or Has Acceleration Flat Spot ………….. 72
Engine Will Not Run at Recommended RPM ……………………………………. 72
Ignition System Description …………………………………………….. 73
Ignition Coil Test ……………………………………………………… 73
Pickup Coil Test ……………………………………………………….. 74
Ignition Module Test ……………………………………………………. 75
Inductor ………………………………………………………………. 75
Distributor ……………………………………………………………. 75
Setting Initial Timing …………………………………………………. 78
Setting Timing ………………………………………………………… 78
Ignition Coil Replacement ………………………………………………. 79
Ignition and Pickup Coils ……………………………………………….. 81
Specifications …………………………………………………………. 81
Ignition System Problems ……………………………………………….. 82
Torque Specifications …………………………………………………… 83
Section 4A.pdf…………………………………………………………………. 0
Contents…………………………………………………………………… 84
Important Preliminary Checks …………………………………………….. 87
Hard Start Symptom ……………………………………………………… 88
Surges Symptom …………………………………………………………. 89
Hesitation, Sag, or Stumble Symptom ………………………………………. 90
Detonation / Spark Knock Symptom …………………………………………. 91
Lack of Power, Sluggish, or Spongy Symptom ………………………………… 92
Cuts Out, Misses Symptom ………………………………………………… 93
Rough, Unstable or Incorrect Idle and Stalling Symptom ……………………… 94
Backfire (intake) Symptom ……………………………………………….. 95
Backfire (exhaust) Symptom ………………………………………………. 96
Dieseling, Run-On Symptom ……………………………………………….. 97
Poor Fuel Economy Symptom ……………………………………………….. 98
ECM J1 Connector and Symptoms Identification ………………………………. 99
ECM J1 Connector and Symptoms Identification (cont.) ………………………..100
ECM J2 Connector and Symptoms Identification ……………………………….101
Section 6A.pdf…………………………………………………………………. 0
Contents……………………………………………………………………130
Section 7A.pdf…………………………………………………………………. 0
Contents……………………………………………………………………154
DTC 14 – Engine Coolant Temperature (ECT) Sensor Low Temperature Indicated ……155
DTC 15 – Engine Coolant Temperature (ECT) Sensor – High Temperature Indicated ….157
DTC 21 – Throttle Position (TP) Sensor – Signal Voltage High …………………159
DTC 22 – Throttle Position (TP) Sensor – Signal Voltage Low ………………….161
DTC 33 – Manifold Absolute Pressure (MAP) Sensor – Signal Voltage High ………..163
DTC 34 – Manifold Absolute Pressure (MAP) Sensor – Signal Voltage Low …………165
DTC 41 – Ignition Control (IC) – Open IC Circuit ……………………………167
DTC 42 – Ignition Control (IC) – Grounded IC Circuit, Open or Grounded Bypass ….169
DTC 44 – Knock Sensor (KS) – System Inactive ……………………………….171
DTC 51 – ECM Calibration Memory Failure ……………………………………173
Engine Protection Mode Circuit …………………………………………..175
Wiring Diagrams…………………………………………………………………438
4.3GXi-A_5.0GXi-A_5.7Gi-A_5.7GXi-B…………………………………………….438
4.3GXi-B……………………………………………………………………440
4.3GXi-C/D………………………………………………………………….442
50GXi-B_57Gi-B_57GXi-C……………………………………………………….444
50GXi-C/D_57Gi-C/D_57GXi-D/E………………………………………………….446
81Gi-B, 81GXi-A……………………………………………………………..448
81Gi-C/D, 81GXi-B/C………………………………………………………….450
DPX375-B_DPX420-B.pdf………………………………………………………..452
Safety…………………………………………………………………………454
Part A……………………………………………………………………..455
Part B……………………………………………………………………..464
Section Covers 1.pdf……………………………………………………………. 0
General Information ………………………………………………………… 8

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