Volvo Penta 5.0L – 5.7L GL, Gi, GXi, OSi, OSXi Service Workshop Manual

Workshop Service and Repair Manual for the 5.0L & 5.7L Volvo Penta engines This full workshop manual set covers every component, service and repair procedure including the EFI system in full Volvo Penta factory specification with clear concise step by step photographs and technical drawings for the 5.0L & 5.7L units with torque setting values throughout where required for fasteners, below is an exhaustive list of the items covered within this set. This is the most comprehensive service manual set available as used by marine engineers and boatyards the world over.

WORKSHOP MANUAL 176 Pages

The full workshop manual covering the strip down, repair and rebuild of the engine covering the unit variants below:

5.0 GL
5.7 Gi
5.0/5.7 GXi
5.0/5.7 OSi, 5.7 OSXi

General Description
Tools and Shop Equipment
Accessories
Cleaning
Draining The Engine
Engine Lubrication
Exhaust Manifold
Starter
Intake Manifold
Remove Distributor, Gi and GXi Models
Disassemble Intake Manifold (Gi, GXi, OSi, & OSXi)
Assemble Intake Manifold
Intake Manifold Installation
Distributor Installation
Rocker Arm Cover
Valve Train
Valve Lifters and Guides Clean and Inspect
Valve Lifter Installation
Valve Lifter Pushrod Guides
Valve Push Rod
Install Rocker Arm Assemblies
Valve Lash Adjustment.
Valve Rocker Arm Cover Installation
Cylinder Head
Cylinder Head Disassemble and Recondition
Cylinder Head Clean and Inspect
Valve Spring Straightness
Valve Stems
Valve Guide Reaming and Seat Grinding
Valve Rocker Arm Stud Removal
Valve Rocker Arm Stud Installation
Cylinder Head Assembly
Install Oil Seal
Oil Pan and Oil Pump
Oil Pan Clean and Inspect
Oil Pump Disassemble
Oil Pump Clean and Inspect
Water Pump
Water Pump Installation
Crankshaft Balancer
Crankshaft Balancer Inspect
Crankshaft Balancer Installation
Engine Front Cover
Engine Front Cover Installation
Timing Chain and Sprocket
Camshaft
Camshaft Bearings
Piston, Connecting Rod, and Bearings
Piston and Connecting Rod Disassemble /Clean and Inspect
Piston Selection
Engine Coupler
Flywheel
Crankshaft Rear Oil Seal and Housing
Crankshaft
Crankshaft and Bearings Clean and Inspect
Bearing Clearance Measuring Procedures
Micrometer Method for Crankshaft Bearings
Recondition Engine Block
Engine Block Plug
Engine Block Clean and inspect
Cylinder Boring and Honing
Boring Procedure
Engine Specifications 5.0 Litre
Engine Specifications 5.7 Litre
Fastener Tightening Specifications
Sealants, Adhesives and Lubricants
Tune-Up Specifications
Special Tools

EGC DIAGNOSTICS 316 Pages

Covering fault finding and general diagnosis of every possible problem and the procedures for rectification for the engines listed below:
4.3GXi-F(F), 4.3OSi-F(F)
5.0GXi-F(F), 5.0OSi-F(F)
5.7Gi-F(F), 5.7GXi-G(F)
5.7OSi-E(F), 5.7OSXi-E(F)
8.1Gi-G(F), 8.1GXi-F(F), 8.1OSi-C(F)

GENERAL INFORMATION:
Intake Manifold Vacuum Testing
Gasoline Requirements
Gasoline Containing Alcohol
Crankcase Oil
Off-Season Storage
Prepare a storage mixture
Change Motor Oil and Oil Filter
Change Sterndrive Lubricant
Drain Cooling System
Preparation for Boating After Storage
Engine Break-in
Submerged Engine
20-Hour Check
Belt Tension
Positive Closed-Type Ventilation System
5.0L and 5.7L engines only
Troubleshooting – System Isolation
Engine Troubleshooting Guides
Engine Will Not Crank
Engine Cranks, But Will Not Start
Hard Starting – Cold Engine
Hard Starting – Hot Engine
Engine Runs Rough
Engine Noises and Vibrations
Engine Overheats
Engine Dies Out
Engine Won’t Reach Operating RPM
Defective Engine Lubricating System
Low Battery Voltage After Short Storage
Abbreviations

SYSTEM DESCRIPTION:
Visual / Physical Inspection
Basic Knowledge and Tools Required
Electrostatic Discharge Damage
Engine Wiring
Engine Control Module (ECM) Self-Diagnostics
Malfunction Indicator Lamp (MIL)
Intermittent Malfunction Indicator Lamp (MIL)
Reading Diagnostic Trouble Codes (DTC’s)
Service Mode
Normal Mode
On-Board Diagnostic (OBD) System Check
DLC Scan Tools
Special Tool and Equipment

SYMPTOMS:
On-Board Diagnostics System Check (OBD)
Malfunction Indicator Lamp (MIL)
Circuit Description
Preliminary and Intermittent Checks
Hard Starting
Surging
Hesitation, Sag or Stumble
Detonation/Spark Knock
Lack of Power, Sluggish or Spongy
Cuts Out, Misses
Rough, Unstable, or Incorrect Idle; Stalling
Backfire
Dieseling, Run-On
Poor Fuel Economy
ECM Connector Identification
4.3 L Engines
5.0 and 5.7 L
8.1 L

Diagnostics with full DTC codes

ECM Limits

Vodia Index by Number

EFI DIAGNOSTICS 469 Pages

Full diagnostic information covering faults with the EFI system complete with DTC codes

Circuit Protection
Circuit Protectors And Locations
Battery And Cables
Special Tools required: Battery Hydrometer
Battery Requirements
Battery Maintenance
Cable Requirements
Tuning The engine
Gasoline Requirements
Gasoline Containing Alcohol
Storage
Prepare A Storage Mixture
Electric Fuel Pumps And Fuel Cells
Stuck Pumps
Noisy Pumps
Periodic Maintenance Chart
Abbreviations
Aftermarket (Add-on) Electrical And Vacuum Equipment
Visual/Physical Inspection
Basic Knowledge And Tools Required
Electrostatic Discharge Damage
Engine Wiring
Engine Control Module (Ecm) Self-diagnostics
Malfunction Indicator Lamp (Mil)
Intermittent Malfunction Indicator Lamp (Mil Reading Diagnostic Trouble Codes (Dtc’s) Service Mode
Normal Mode
On-board Diagnostic (Obd) System Check
Dlc Scan Toolsscan Tool Use With Intermittents
How Diagnostic Trouble Codes (Dtc) Are Set
Clearing Diagnostic Trouble Codes (Non-scan)
Clearing Diagnostic Trouble Codes (Scan)
Non-scan Diagnosis Of Drivability Concerns (No Dtc’s Set)
Service Precautions
Special Tools And Equipment
Wiring Harness Service
Wiring Connector Service
Metri-pack Series 150 Terminals
Weather-pack Connectors
Micro-pack 100/W Series Connectors

EFI REPAIR 138 Pages

A fully comprehensive repair guide for the EFI fueling system of the units listed below:

5.0GXi, 5.0OSi
5.7Gi, 5.7GiI 5.7GXi, 5.7GXiI 5.7OSi, 5.7OSXi

Repair Instructions
Fuel Control On-Board Service
Fuel Pressure Relief Procedure
Engine Cover
Fuel Pressure Relief Procedure
Quick Connect Fittings Service
Flame Arrestor
Engine Control Module (ECM)
System/Ignition Relay
Fuel Pump Relay
Engine Coolant Temperature Sensor (ECT)
T-MAP Sensor
Throttle Position Sensor (TPS)
Idle Air Control Valve (IAC)
Throttle Body Assembly
Fuel Rail Assembly
Fuel Pressure Regulator
Fuel Injector
Distributor
Ignition Coil
Ignition Control Module
Fuel Cell
High-Pressure Fuel Pump Replacement
Spark Plug
Spark Plug Wire Inspection
Spark Plug Wire Replacement
Spark Plug Inspection
Spark Plug Visual Inspection
Crankshaft Position (CKP) Sensor
Camshaft Position Sensor (CMP)
Knock Sensor
Temperature v. Resistance IAT and ECT
Ignition System Specifications – 4.3L
Ignition System Specifications – 5.0L and 5.7L
Fuel System Specifications
Fastener Tightening Specifications

ENGINE OVERHEAT DIAGNOSIS 15 Pages

A priceless guide for unfathomable overheating issues

Introduction.
Six-step Troubleshooting Method
Diagnostic Tips.
Clear Hose Testing Equipment
Clear Hose Setup (Pump)
Clear Hose Setup (Engine)
Gauge Readings At The Raw Water Pump
Troubleshooting Raw Water Cooled Engines With Clear Hoses And Gauges
Troubleshooting Closed Cooling System Engines With Clear Hoses And Gauges
Water Inlet System Flushing
Water Inlet System Testing
Leak Checking And Flow Checking Exhaust Manifolds And Risers
Conclusion

OWNERS MANUAL 88 Pages