Service and Maintenance D4, D6

service and maintenance
D4, D6
© 2017 AB VOLVO PENTA
Volvo Penta reserves the right to make changes
Printed on environmentally friendly paper
Table of Content
Safety Information ...................................................................................... 5
Spare parts - safety ................................................................................... 7
General Information .................................................................................. 14
Service Protocol ...................................................................................... 15
Preventive repair ..................................................................................... 16
Genuine Volvo Penta Parts ..................................................................... 23
Illustrations .............................................................................................. 25
Chemical products .................................................................................... 27
Chemical products .................................................................................. 27
Special Tools ............................................................................................. 29
Other Special Equipment ........................................................................ 29
Specifications ............................................................................................ 31
Engine Decals ......................................................................................... 31
Transmission Decals ............................................................................... 32
General Tightening Torques .................................................................... 34
Specifications .......................................................................................... 35
Engine ........................................................................................................ 40
Component location ................................................................................ 41
Maintenance Schedule ............................................................................ 44
General inspection .................................................................................. 45
General advice for electronic protection .................................................. 47
Check software status ............................................................................. 48
Air Filter ................................................................................................... 48
Crankcase Ventilation, Filter Change ...................................................... 49
Compressor, oil level ............................................................................... 50
Compressor oil, Replace ......................................................................... 50
Lubrication System ................................................................................... 52
When you work with Chemicals, Fuel and Lubrication Oil, Change ........ 52
Engine Oil, Level Check .......................................................................... 52
Engine oil, Replace ................................................................................. 54
Oil filter, Replace ..................................................................................... 55
Oil topping up and level check ................................................................ 56
Fuel System ............................................................................................... 64
General ................................................................................................... 64
Fuel filter, Change ................................................................................... 65
Fuel pre-filter ........................................................................................... 66
Fuel system, bleeding ............................................................................. 68
Exhaust System ........................................................................................ 71
Exhaust hose .......................................................................................... 71
Turbocharger, Inspection ........................................................................ 72
Cooling System ......................................................................................... 74
Coolant Level, Checking and Topping Up ............................................... 74
Drive Belt, Replace ................................................................................. 77
Seawater Pump, Impeller, Change ......................................................... 80
Seawater Filter, Check and Cleaning ...................................................... 82
Anodes .................................................................................................... 84
Transmission ............................................................................................. 86
IPS ........................................................................................................... 86
IPS ....................................................................................................... 86
Oil drain, IPS ........................................................................................ 88
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Oil filter, IPS ......................................................................................... 88
Oil filler, IPS ......................................................................................... 89
IPS, oil level ......................................................................................... 89
Anode, exhaust outlet (IPS) ................................................................. 90
Propeller ............................................................................................... 91
Propeller shaft seals, replacement ....................................................... 92
Transmission: Oil strainer, inner and outer .......................................... 92
Anodes ................................................................................................. 93
Painting IPS Drives .............................................................................. 94
Reversing gear ....................................................................................... 95
Reversing gear, oil and filter change .................................................... 95
Sterndrive ............................................................................................... 99
Valve block, oil filter, change .............................................................. 101
Sterdrive, hydraulic fluids ................................................................... 103
Sterndrive, oil level ............................................................................. 104
Sterndrive, Draining ........................................................................... 107
Sterndrive, Oil Filling .......................................................................... 109
Sterndrive bellows .............................................................................. 111
Propeller ............................................................................................. 112
Checking Protective Anodes .............................................................. 113
Painting the Drive ............................................................................... 115
Long-Term Storage ................................................................................. 117
Storage instruction for long-term storage of new engine ....................... 119
Cleaning engine and transmission ........................................................ 121
Cold Weather Precautions .................................................................... 123
Checklist ................................................................................................ 125
Battery, Maintenance ............................................................................ 126
Index ......................................................................................................... 129
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Safety Information
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Safety Information
Safety Information
This chapter describes how safety precautions are If anything remains unclear or if you are unsure of
presented in the manual and on the product. Read the something, contact your Volvo Penta dealer for
chapter through very carefully before you start the assistance.
engine or do any maintenance or service. It has to do
with your safety; an incorrect operation can lead to IMPORTANT:
personal injury and damage to products or property. It Always follow local safety instructions and
also gives you an introduction to the basic safety rules regulations.
for using and looking after the engine.
Safety texts have the following order of priority:
DANGER!
Indicates a hazardous situation, which, if not avoided, result in death or serious injury.
WARNING!
Indicates a hazardous situation, which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT:
Indicates a situation, which, if not avoided, could result in property damage.
NOTICE! Used to draw attention to important information that facilitates work or

operations.
!
This symbol is may be used on the product to call your attention to the fact that this is
safety information. Always read such information very carefully.
Make sure that warning and information symbols on the engine are clearly visible and
legible. Replace symbols that have been damaged or have been painted over.
In some cases, this symbol is used on our products and refers to important information
in the Operator’s Manual.
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Safety Information
Most chemicals such as engine and transmission oils,

glycol, petrol and diesel oil and chemicals used in
workshops such as degreasing agents, paint and
solvents are harmful to health.
Carefully read the instructions on the product

packaging! Always follow the safety regulations, such
as the use of protective masks, goggles, gloves, etc.
Make sure that other personnel are not exposed to
substances that are hazardous to health. Ensure good
ventilation.
Manage used and leftover chemicals in the prescribed

manner.
Personal safety equipment

CAUTION!
Always use appropriate safety equipment. Personal
protective equipment does not eliminate the risk of
injury but it will reduce the degree of injury if an
accident does happen.
Some examples are ear protection, eye and face

protection, protective footwear, personal protective
equipment, head protection, protective clothing,
gloves and respirators.
WARNING!
Ensure that all machine guards and safety devices are
in place and are functional.
P0024482
CAUTION!
Never use tools or products that show signs of
damage.
Protect your eyes

CAUTION!
Wear safety glasses.
Always wear safety glasses if there is a risk of

splintering, sparks and spray from the electrolyte (so-
called battery acid), or other chemicals. Your eyes are
very delicate and damage can result in loss of sight!
Protect your skin

CAUTION!
Risk of skin damage.
Avoid getting oil on your skin! Prolonged or repeated

exposure to oil can dry out the skin. Thereafter,
irritation, dryness and eczema and other skin problems
may occur.
Use protective gloves and avoid oil-soaked clothes

and rags. Wash regularly, especially before eating.
Wear suitable protective creams to prevent skin from
drying out and to facilitate cleaning.
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Safety Information
Fire safety
WARNING!
Fire and Explosion Risk!
Accidental spark could ignite fuel vapors.
All fuels – as well as many lubricants and chemicals –

are flammable. Do not allow open flames or sparks
near them. Smoking forbidden! Hydrogen from the
batteries is also very flammable and explosive in
certain mixture with air.
Ensure that the workplace is well ventilated and take

the necessary precautions before welding or grinding
begins. Always ensure that there is a fire extinguisher
close at hand in the work area.
P0024470
Spare parts - safety

WARNING!
Always use Volvo Penta genuine spare part to
minimize the risk of an explosion or fire.
Components in fuel systems and electrical systems on

Volvo Penta engines are designed and manufactured
to minimize the risk of explosions and fire, in
accordance with applicable legal requirements.
Used oils, filters and chemicals etc.

WARNING!
Risk of fire.
Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire.
Oil-soaked rags can spontaneously ignite under

certain circumstances.
IMPORTANT:
Used fuel and oil filters are environmentally hazardous
waste and must be taken to an approved waste
management facility for correct handling, as must any
used lubricating oil, contaminated fuel, paint residue,
solvents, degreasers and wash residue.
Prevent start of the engine

WARNING!
Immobilize the engine by turning off the power supply
with the main switch(es) and lock it (them) in the off
position before starting work. Place a warning notice at
the main switch.
If the engine is equipped with BMS (Battery
Management System), always disconnect both battery
cables from the battery terminals.
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Safety Information
Ventilation when running the engine

WARNING!
Only start the engine in a well-ventilated area. If
operating the engine in a closed area ensure that there
is exhaust ventilation leading out of the work area to
remove exhaust gases and crankcase ventilation
P0024481 emissions.
The engine must not be operated in areas where there

are explosive materials or stored gas.
Rotating parts and hot surfaces

DANGER!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
If the engine is in operation and operates another
device, you must not, under any circumstances,
staying close to the engine.
P0024808
Work on running engines is strictly prohibited. There
are however adjustments that require the engine to be
run. Approaching a running engine is a safety risk.
Loose clothing and long hair can get caught in the
rotating parts; careless movements or a dropped tool
can lead to serious personal injury.
Be careful to avoid hot surfaces (exhaust pipes,

turbochargers, charge air manifolds, start elements
etc.) and hot fluids in pipes and hoses on engines that
are running or have just stopped. Re-install all
protective covers that were removed during
maintenance work before starting the engine.
Information on the engine

IMPORTANT:
Make sure that all warning and information decals on
the product are always visible. Replace decals which
have been damaged or painted over.
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Safety Information
Prohibition on use of start spray

WARNING!
Never use start spray or similar agents to start an
engine. This may cause an explosion in the inlet
manifold. Risk of personal injury.
P0024483
Before start of engine

WARNING!
Never start the engine if there is reason to suspect fuel
and/or gas leaks, or if there is explosive material
nearby.
IMPORTANT:
Only start the engine with the air filter and protective
caps fitted. Foreign objects in the inlet line could cause
machine damage. Also make sure that no tools or other
P0024688 parts have been left next to the engine.
WARNING!
Never start the engine with the valve cover removed.
There is a risk of personal injury.
For engines with turbochargers, the rotating
compressor turbine can in addition cause serious
personal injuries.
Before any work on the electrical system

WARNING!
Always stop the engine first. Then disconnect the
current at the main switches and any external power
supply before working on the electrical system – to
minimize the risk of electrical hazards.
IMPORTANT:
Never disconnect the current using the main switches
when the engine is running or by disconnecting the
battery cables.
The alternator and electronics could be damaged.
Avoid damage to the engine control

module and other electronics
IMPORTANT:
Switch off the main switch before connecting or
disconnecting a connector.
Before any work on the cooling system

WARNING!
Stop the engine and let it cool before starting work on
the cooling system. Hot fluids and hot surfaces can
cause burns.
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Safety Information
Risk of water penetration/sinking

WARNING!
If a launched boat is equipped with sea water tap and
safety valve, ensure that these are closed before any
work is allowed to begin on the cooling system.
Remember to open the tap and valve before starting
the engine!
P0024484
Hot coolant under pressure

CAUTION!
Hot coolant can cause burns. Avoid opening the filler
cap for the coolant when the engine is still hot. Steam
or hot coolant can spray out and system pressure is
lost.
Open the filler cap slowly, and release the pressure in

the cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose must be removed
from a hot engine.
Hot oil under pressure

CAUTION!
Hot oil can cause burns. Avoid getting hot oil on the
skin. Ensure that the lubrication system is not
pressurized before starting any work. Never start or
operate the engine without the oil filler cap is on. There
is a risk that hot oil can spray out.
At any leak detection on the fuel system

WARNING!
Wear safety goggles!
Be extremely careful when searching for leaks in the
fuel system high-pressure circuits. There is very high
pressure in the jet from pipes and injectors. The fuel
may penetrate the tissue and cause serious risk of
P0024488
blood infection (septicemia).
Handling of fuel pipes

IMPORTANT:
High pressure pipes for fuel must not be bent or
straightened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.
Before any work on the fuel system —

Cleanliness
IMPORTANT:
Take great care to keep the fuel system components
clean. Even minimal amounts of dirt can cause engine
breakdown.
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Safety Information
Safe handling of batteries

WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the batteries.
A spark caused by an incorrectly connected battery

can be sufficient for the battery to explode resulting in
serious injury and damage.
Do not touch the connections during a starting attempt.

Spark hazard! Do not lean over batteries.
Correct polarity of the batteries

IMPORTANT:
Make sure that the positive (+) and negative (–) battery
cables are correctly connected to the corresponding
battery terminals. Wrong connection may cause
severe damage to electrical equipment.
P0024468
Risks of electrolyte in batteries

WARNING!
Always wear protective goggles when charging or
handling batteries.
Battery electrolyte is highly corrosive.
Rinse immediately with copious amounts of water if the

electrolyte gets in your eyes. Search directly after the
rinsing help by medical staff.
If it comes electrolyte to unprotected skin, wash

immediately with soap and water.
After finished work with the engine

IMPORTANT:
Always perform a leakage and function check.
Cleaning the engine and components

NOTICE! Follow the instructions Cleaning engine and
transmission, page 121.
P0026213
Cleanliness for sensitive components

IMPORTANT:
Observe meticulous cleanliness when handling
system components.
Even minimal amounts of dirt could cause a
breakdown.
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General Information
Lifting the engine

WARNING!
Never work alone when removing heavy components,
even when using lifting devices such as locking tackle
lifts.
IMPORTANT:
P0024485 When using a lifting device, two people are usually
required to do the work – one to take care of the lifting
device – and the other to ensure that components are
lifted clear and not damaged during the lifting
operations.
Proper lifting equipment

DANGER!
The existing lugs on the engine should be used for
lifting. Always check that the lifting equipment used
is in good condition and has the load capacity to lift
the engine (engine weight including transmission and
extra equipment). For safe handling and to avoid
damaging components fitted to the top of the engine,
the engine must be lifted with a correctly adjusted lifting
boom.
Never perform any work on an engine that is only
suspended from the lifting equipment.
IMPORTANT:
All chains or wires must run parallel to each other and
as perpendicular to the engine as possible. If other
equipment attached to the engine has altered its center
of gravity, special lifting devices may be needed to
obtain the correct balance for safe handling.
P0024689
Example of an adjustable lifting yoke and a lifting tool.
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General Information
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General Information
General Information
General information Specific terms for the U.S. market
This service and maintenance manual contains This engine is certified as being in compliance with
descriptions and instructions for the service of the federal and Californian exhaust restriction
above-mentioned Volvo Penta products in their regulations. Parts related to exhaust restrictions are
standard models. The design and servicing items may covered by the warranty commitment for exhaust
vary between different products. Applicable service restricting systems. Terms and the parts covered are
intervals and service procedures are described in the specified under "What is covered by the warranty
maintenance schedule for the product. undertaking for emissions” in “Emission Control
System Warranty Statement”. Repairs and service
The product designation, serial number and covered by the warranty are carried out by an
specification are indicated on the engine decals or authorized Volvo Penta distributor or dealer at no
type plate. This information must always be provided charge for diagnostics, labor or parts using genuine
in all correspondence concerning the product. Volvo Penta parts in all areas of the exhaust restriction
system covered by the warranty and found to be
The manual has been produced primarily for use in
defective.
Volvo Penta workshops. It is assumed that persons
using the manual have fundamental knowledge of the The use of the service and repair workshop other than
product and are capable of carrying out mechanical a Volvo Penta authorized distributor or dealer or the
and electrical work to industry standards. use of exhaust-related components from other
manufacturers than Volvo Penta do not affect the
Volvo Penta continually develops its products. We
scope of the warranty undertaking for emission-
therefore reserve the right to make changes.
restricting systems. If emission-related components/
All of the information in the manual is based on
items are included in scheduled service, such parts
product data available when the manual was
are marked with a diamond (♦) in the maintenance
published.
schedule and service must be carried out at the
NOTICE! The owner is responsible for ensuring that specified intervals in order to meet the requirements
scheduled maintenance is carried out. Warranty of the warranty undertaking for emission-restricting
claims to Volvo Penta may be declined if neglected systems. The full warranty terms can be found in
maintenance results in faults in the specified product. “Emission Control System Warranty Statement”.
Refer to the warranty terms supplied with the engine.
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General Information
Certified engines
Explanation of the relationship between
The engine is exhaust-certified, and if it is used in
an area where exhaust emissions are regulated
service intervals and operating
by law, this places special demands on the care conditions
and maintenance of the engine. Because operating conditions may vary depending
NOTICE! Neglect or failure to follow the items on how the component is used, it is important that the
required here may invalidate the engine emissions service interval (expressed in hours or months) is not
certificate. exceeded.
This means that AB Volvo Penta will no longer be able Example: 1000 hours / 24 months. Whichever is the
to assume liability for engine specification sooner applies. If the component is used for 1000
compliance with the certified model. Volvo Penta is hours in 18 months, the service must be carried out
not responsible for damages or costs arising as a when the 1000-hour interval is reached.
result of this.
This is to retain the component’s best quality and
• Certification means that an engine type has
service life. The warranty will be void if this is not
been inspected and approved by the competent
complied with.
authorities. The engine manufacturer
guarantees that all engines made of the same Typical examples are: Propeller shaft seals operating
type are equivalent to the certified engine. in sandy waters. Air filters exposed to heavily polluted
• It is the responsibility of the user to make sure air
no intentional misuse of the engine takes place.
Action codes used in the service schedule:
• Volvo Penta maintenance and service intervals C = Cleaning
must be followed. R = Replacement
A = Adjustment
• All faults must be remedied as soon as possible.
L = Lubricate
• Only use genuine Volvo Penta replacement I = Inspection (includes where necessary also
parts or parts of the same quality as Volvo Penta adjustment, cleaning, lubrication and replacement)
replacement parts.
• The engine may not be converted or modified in
any way, except with accessories and service
kits which Volvo Penta has approved for the
engine.
• Volvo Penta recommends that service on
injection pumps, pump settings and injectors
always be carried out by a qualified workshop.
• No changes may be made to the installation of
the exhaust pipe and engine air inlet ducts.
• Any tampering with the engine will hamper EU
type-approval of the engine concerned.
• No warranty seals (if present on the product)
may be broken by unauthorized persons.
Service Protocol
To maintain the functionality of the product Service
Protocol shall be followed. The owner or other persons
with sufficient technical competence may carry out
some measures in accordance with Service Protocol.
Contact an authorized Volvo Penta dealer in the case
of uncertainty as to how service work must be
performed.
Service Protocol contains the necessary maintenance

points for your engine in a single document. See more
on Volvo Penta‘s website: vppn.volvo.com and
Product Center for online service protocol.
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General Information
Preventive repair
Here is an overview of the components that may be included in preventive maintenance. May vary depending on
the engine's design and construction.
These components form the basis for calculating service contracts and the costs in the service calculator in
Product Center.
Fuel system
Fuel pump
Unit injectors
P0026295
Exhaust system
Turbocharger, low-pressure
Turbocharger, high pressure
Overflow valve (Lisk)
Silencer
Diesel particulate filter (DPF), replacement
After-treatment system
Pump unit
Dosage valve
P0026296
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General Information
Cooling system
Seawater pump
Coolant pump
Engine
Vibration dampers
Engine pads, kit
P0026297
Electrical system
Alternator
Starter motor
P0026298
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General Information
Engine, overhaul
Here is an overview of the components that may be included in a complete overhaul. May vary depending on the
engine's design and construction.
E.g. liners may not be replaced on certain engines. In this case, cylinders must be measured to see if new pistons
can be installed or if the engine block should be replaced.
The components below provide the basis for calculating service contracts and the costs in the service calculator
in Product Center.
Engine: May be overhauled twice, after which the engine is considered spent and is replaced by a long block or
new engine.
Overhaul
Long block
Short block
Cylinder head (replacement)
Cylinder head, gasket
P0026299
Engine, overhaul kit

Cylinder head, overhaul kit
Gaskets, kit
Flat gaskets
Valve cover, gasket
P0026300
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General Information
Cylinder liners, kit

Main bearings, kit
Big end bearings, kit
Thrust washers, kit
Camshaft bearings, kit
P0026301
Exhaust valve
Valve seat
P0026302
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General Information
Transmission, overhaul
Here is an overview of the components that may be included in a complete overhaul/replacement. May vary
depending on the transmission's design and construction.
The components below provide the basis for calculating service contracts and the costs in the service calculator
in Product Center.
The transmission is overhauled once, then the complete unit is replaced
Overhaul, Aquamatic
Aquamatic sterndrive, replacement
Upper gear
Lower gear
P0026303
Repair, Aquamatic
Upper gear, kit
Sliding sleeve
P0026304
Lower gear, kit
P0026305
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General Information
Overhaul, IPS
IPS Drive, replacement
Upper gear
Lower gear
P0026306
Repair, IPS
Upper gear, kit
P0026307
Lower gear, kit
P0026308
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General Information
Propeller shaft
P0026309
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General Information
Genuine Volvo Penta Parts

Volvo Penta products are designed and manufactured
to achieve the highest quality. All parts are
manufactured so that together they provide the best
possible reliability. For this reason, we always
recommending the use of Genuine Volvo Penta
Partsas they are manufactured based on the same
stringent specifications as the factory-installed parts in
Volvo Penta powertrains.
Lube oils
Volvo Penta supplies a wide range of lubricants
developed especially for Volvo Penta engines. VDS
(Volvo Drain Specification) is a Volvo standard that
specifies Volvo’s oil grade requirements. We
recommend the use of the specified oil to ensure
engine function and a long service life.
Transmission oil
In a marine environment it is vitally important that the
correct gear lubricant is used for the product
concerned.
In Volvo Penta's extensive testing we pick out those
oils that meet our requirements for functionality and
that within the oil change intervals ensure the product’s
service life.
While oils from various suppliers meets both SAE class
(viscosity) and API class (quality), their additives often
differ. Additives can be up to 35% of the total volume,
and are crucial to how oil can handle a given water
content while still maintaining the necessary
lubricating properties. The additives also affect the
friction in, for example, the IPS unit clutch assembly.
The correct oil is crucial for the proper functioning of
the transmission.
IMPORTANT:
It is extremely important not to use other oil than
specified for the IPS unit.
NOTICE! Volvo Penta will deny all warranty claims if it

emerges that the wrong oil has been used in the IPS
unit.
NOTICE! For reverse gears, the oil change intervals

and maintenance instructions recommended by the
manufacturer must be adhered to.
Coolant
The main function of a coolant is to absorb heat from
the engine. The coolant also protects against freezing,
lime deposits and corrosion. Volvo Penta Coolant VCS
(yellow) and Volvo Penta Coolant (green) are two
completely different types of coolants, which contain
different types of inhibitors. Different types of coolants
(colors) must not be mixed.
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General Information
If the concentrated coolant must be diluted with water,

the water's chemical composition may impair the
corrosion protection. In areas with high levels of
sodium and calcium in tap water, the coolant must be
diluted with distilled water. Alternatively, Volvo Penta
coolant is available for purchase ready diluted.
Protection against
Mixing the freeze bursting down
concentrated coolant to:
40 % -25 °C
46 % -30 °C
54 % -38 °C
60 % -46 °C
NOTICE! It is important to use coolant with a

concentration of 40-60 % in the cooling system even
where there is no risk of freezing. The coolant also
prevents corrosion and deposits. A mixture with a
concentration above 60 % will impair antifreeze
protection.
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Chemical products
Illustrations
Colors used in illustrations

• Highlighted components
Most illustrations include a highlighted component
(blue)
which is secured by a bolt or similar as part of a (light
gray) engine or transmission. • Fastener
(red)
• Assembly
(light gray)
• Background
(white)
• Special tools
(yellow)
• Seals
(green)
(as of 06/2018)
P0022106
Other types of symbols used in the images are

divided into the following categories:
• Safety
• Important
• Cleanliness
• Position
• Movement
• Measured value
• Tools
• Chemicals
• Sealant
• Units
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Chemical products
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Special Tools
Chemical products
Chemical products
The following is a selection of Volvo Penta
recommended chemical products. The products are
available for purchase at regional Volvo Penta
dealerships. Deviations may occur in the range, see
Specifications.
For correct part numbers, refer to the Parts catalogue.
P0001869
Thread locking fluid Corrosion protection Sealant
Engine oil Transmission oil IPS synthetic gear lubricant
VCS Coolant Grease ATF oil
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Special Tools
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Specifications
Special Tools
Other Special Equipment
There are special equipment and tools to be used
when working with the engine. For some operations/
service points special tools are required in order to
carry out the work in a correct manner.
3889988 Adapter 22767251 Hose
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Specifications
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Specifications
Specifications
Engine Decals
There are type plates on the engine, and in the case of
marine applications, also on the drive lines. Some of
the type plates are marked with identity numbers. This
information should always be used as a reference
when ordering service and replacement parts or
contacting Volvo Penta retailers.
1 Certification/Transom ID 3 Serial #
2 CHASSIS ID 4 Product ID
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Specifications
Transmission Decals
IPS unit
1 Product ID
2 CHASSIS ID
Reverse Gear
1 Reverse gear ID
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Specifications
Stern drive
1 Stern drive ID
Electrical rudder actuator

1 Product information
2 CHASSIS ID
3 Product ID
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Specifications
General Tightening Torques

Bolt Nm
M6 standard bolt 10
M8 standard bolt 24
M10 standard bolt 48
NOTICE! Check the bolts intended for
installation Damaged bolts with e.g. shear
marks under the heads, must be scrapped.
34 47707967 09-2022 © AB VOLVO PENTA

Specifications
Specifications
Volvo Penta products, all markets excluding North America

Oil quantity in engine, including filter
D4 12 liters
D6 20 liters
VDS-4.5 SAE15W-40
Part number: 23909459 1 liter
Part number: 23909460 5 liters
Oil volume
DPH-D1 drive 5.1-5.3 liters
(differs between versions: A - B - C - D)
DPR drive 4.2 liters
Transmission oil DPH gear ratio 1.59 (D6 - 400hp) 5 liters

SAE 75W-140. Part number: 3809439
DPH/DPR transmission oil 5 liters
Power Trim Hydraulic oil

ATF/Dextron. Part number: 1161995
Oil quantity, IPS oil including filter

D4 14 liters
D6 14 liters
Transmission oil IPS
Part number: 22479650 1 liter
Transmission oil, reverse gear 5 liters

Rudder actuator
Oil: ATF/Dextron. Part number: 1161995
Oil volume 5 liters
Oil, compressor. Part number: 85108974 0.1 liter
Coolant, VCS yellow, concentrated

Coolant, VCS yellow, ready-mixed
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Specifications
Volume ready-mixed coolant VCS, (empty system)

D4 13 liters
D6 16 liters
Propeller shaft grease. Part number: 828250 25 grams
NOTICE! Old model engines have green coolant,

which must NOT be mixed with newer VCS yellow
coolant. Check that the engine is using the same type.
NOTICE! Yellow and red Volvo Penta ATF Dextron III

oil may be mixed without causing any problems.
36 47707967 09-2022 © AB VOLVO PENTA

Specifications
Volvo Penta products for North America

Oil quantity in engine, including filter
D4 3.2 gallons
D6 5.3 gallons
VDS–4.5
Part number: 23219282 1 US quart
Part number: 23219274 1 US gallon
Part number: 23219264 5 gallons
Oil volume
DPH-D1 drive 1.3-1.4 gallons
(differs between versions: A - B - C - D)
DPR drive 1.1 US gallon
Transmission oil DPH gear ratio 1.59 (D6 - 400hp) 1 US gallon

DPH/DPR transmission oil 1 US gallon
Power Trim Hydraulic oil 1 US gallon

Oil volume, Transmission oil, including filters

D4 3.7 gallon
D6 3.7 gallon
Part number: 1141679 1 US quart
Part number: 1141680 1 US gallon
Transmission oil, reverse gear 1 US gallon

Oil, rudder actuator: ATF/Dextron. Part number: 3851039

Oil volume in rudder actuator 1.3 gallons
Oil, compressor. Part number: 85108974 0.26 gallons
Coolant, VCS yellow, concentrated

Part number: 22567295 1.3 gallons
Coolant, VCS yellow, ready-mixed
Volume ready-mixed coolant VCS, (empty system)
D4 3.4 gallons
D6 4.2 gallons
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Engine
Propeller shaft grease. Part number: 828250 25 grams
NOTICE! Old model engines have green coolant,

which must NOT be mixed with newer VCS yellow
coolant. Check that the engine is using the same type.
NOTICE! Yellow and red Volvo Penta ATF Dextron III

oil may be mixed without causing any problems.
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Engine
47707967 09-2022 © AB VOLVO PENTA 39

Engine
Engine
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Engine
Component location
1. Coolant 6. Seawater drain

2. Seawater filter 7. Seawater impeller
3. Fuel filter 8. Cooling system drain
4. Oil dipstick 9. Seawater drain
5. Oil filter
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Engine
P0026214
10. Anode, Aquamatic model 14. Compressor (on those engines that have this).
11. Crankcase separator 15. Engine oil filler
12. Oil drain 16. Drive belt cover
13. Air filter
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Engine
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Engine
Maintenance Schedule
The Volvo Penta engine and its equipment are designed for high reliability and long life. The engine is built so as
to have minimal environmental impact. These qualities will be retained and unnecessary malfunctions avoided if
service is provided according to the maintenance schedule.
Service intervals
Service items can be found in the Service Record available for download at www.volvopenta.com.
Search under tab: Manuals.
Extended service intervals

The interval between engine oil changes may be extended in certain circumstances. To determine whether the
service interval may be extended, Volvo Penta's conditions for extended service intervals must be met and an oil
analysis performed, see Lubrication System, page 57.
The Volvo Penta dealer has further information.
Where both operating hours and calendar times are specified, perform the maintenance item at whichever time is
the sooner.
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Engine
General inspection
General inspection
Make a habit of visually inspecting the engine and
engine compartment before the engine is started and
after operation once the engine is stopped. This will
help you to discover quickly if anything abnormal has
happened, or is about to happen.
This inspection only takes a few minutes, but can

prevent serious malfunctions and expensive repairs.
The images are generic and applicable to all engine

installations. They show only a selection of
components and systems.
The inspection applies to all components in the
systems.
Look especially carefully for fuel leakage

at:
• Injector connections
• Common rail, replacement
• Check all clamped items
• Fuel filter
• Fuel pipe/hoses
• Fuel pump
P0026583
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Engine
Oil leaking turbocharger connections, oil pipes/

hoses, oil sensors, oil filter and oil sump.
Check all clamped items.
P0026582
Coolant leakage on the coolant pump, expansion

tank, coolant cooler, oil cooler, charge air cooler,
coolant sensors, coolant hoses.
Check all clamped items.
P0026581
Also check:
Drive belts
Damaged wiring
Loose wiring
Loose fasteners
Exhaust hoses
Hoses/hose connections to transmissions
WARNING!
Accumulations of fuel, oil and grease on the engine or

in the engine compartment are a fire hazard and must
be removed as soon as they are discovered.
WARNING!
If you discover a leakage of oil, fuel or coolant,

investigate the cause and fix the fault before starting
the engine to avoid the risk of fire.
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Engine
General advice for electronic

protection
The following advice must be complied with to ● Never switch off the current at the main switch when
avoid damage to the engine control unit and other the engine is running.
electronics. ● Never disconnect a battery cable when the engine
is running.
IMPORTANT: ● Switch off the main switches or disconnect the
Switch off the main switch before connecting or battery cables when fast-charging the batteries.
disconnecting a connector.
● NOTICE! It is not necessary to switch off the main
switches during normal maintenance charging.
● Only batteries may be used as a starting aid. A jump
start unit is able to supply very high voltage which
may damage the control unit and other electronics.
● Take extreme care so that the harness terminals do
not come into contact with oil, water or dirt if a
connector is removed from a sensor.
Diagnostics socket location.
P0026215
New model
Old model
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Engine
Check software status

These readings depend on the type of installation and
are carried out using the VODIA diagnostics tool.
• Reading and resetting parameters.

• Reading and erasing any fault codes (DTC).
P0024905 • Resetting service intervals (EVC2).
Air Filter
Replacing the air filter

1 Remove the plastic cover that sits over the air
filter.
2 Change the filter (1).
3 Install the cover.
NOTICE! Discard the old filter. It is not meant to be

cleaned.
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Engine
Crankcase Ventilation, Filter

Change
NOTICE! Emission-related component/object.
Replacement of crankcase separator (old model)

1 Remove the cover (1).
2 Replace filter (2).
3 Install the cover.
NOTICE! Discard the old filter. It is not meant to be

cleaned.
Replacement of crankcase separator (new model)

1 The new model does not require any service.
P0026216
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Lubrication System
Compressor, oil level
Checking the level and topping up

1 Unscrew the dipstick.
2 Wipe the oil dipstick dry and put it back in, without
screwing it in.
3 Pull out the oil dipstick again and check the level.
4 Top up with oil as necessary.
NOTICE! Never overfill the compressor with oil. The

level must be inside the marked area on the oil dipstick.
P0026311
Compressor oil, Replace
The compressor oil must be changed at the intervals

specified in the servicing schedule. The oil can be
drained out with the aid of the plug in the bottom (2) or
be sucked out with a hose through the hole for the
dipstick (1).
P0026312
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Lubrication System
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Lubrication System
Lubrication System
When you work with Chemicals,
Fuel and Lubrication Oil, Change
NOTICE! Apply barrier cream to your hands and
always use protective gloves for work which involves
contact with oil, fuel and similar. Continuous skin
contact with engine oil dries the skin and can be
hazardous.
Engine Oil, Level Check

NOTICE! It is very important that engine oil be kept at
a suitable level for correct engine lubrication.
A high oil level leads to increased oil consumption

and may cause clogging of the silencer and/or the
closed crankcase ventilation.
A low oil level may lead to seizing pistons, engine

wear and engine overheating.
Oil level check, hot engine.

• Make sure the engine is level.
• Stop the engine; wait a at least 15 minutes and then
measure the level.
Oil level check, cold engine. (recommended)

• Make sure the engine is level.
• Oil level measurement is most reliable before the
engine is started
Check that the oil level is between the dipstick's min

and max markings.
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Lubrication System
A Oil level on the MIN marking: add oil until the level is
between min and max.
B Optimal oil level, do NOT add oil.
C Oil level at max marking; do NOT add oil.
P0028585
NOTICE! Never add too much engine oil.
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Lubrication System
Engine oil, Replace

1 Remove the rubber protector covering the
connection.
2 Connect a hose to the pipe (1).
3 Empty the oil by siphoning it out with a vacuum
pump.
NOTICE! If the engine oil is hot, it will drain out faster.
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Lubrication System
Oil filter, Replace

NOTICE! Always use original parts and fluids
recommended by Volvo Penta.
1 Remove the oil filters.
2 Lubricate the sealing surface of the gasket (1) on

the new filter with a thin layer of engine oil.
3 Install the oil filters and tighten the filter according
to the filter instructions.
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Lubrication System
Oil topping up and level check
Filling
1 Fill with the required volume of oil; see
Specifications, page 35.
Checking oil level

2 Start the engine and let it idle for a few minutes.
3 Stop the engine and check the oil level after a few
minutes.
4 Top up as necessary.
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Lubrication System
Volvo Penta oil analysis

Volvo Penta oil analysis provides an extensive diagnostic check on the condition of the driveline. The oil analysis
provides information for example on water content, fuel content, dirt and the amount of metallic particles in the oil
as a result of component wear.
Thanks to early warning signs given by oil analysis, preventive maintenance and component replacement can be
planned, so that unplanned shutdowns can be avoided.
Some engines allow the oil change intervals to be extended. There are two different service schedules available for
these engines. Refer to the Volvo Penta Product Center
In order to find out more about Volvo Penta Oil Analysis, we recommend our on-line training.
P0035460
P0024907
IMPORTANT:
This kit and its accompanying instructions have been developed for Volvo Penta's service workshops, boat builders,
machine manufacturers and other authorized workshops that have staff with qualified professional training. The
assembly instructions are intended for professionals only and are not intended for use by laypeople. Volvo Penta
assumes no liability whatsoever for damage to materials or persons that may occur if the assembly instructions are
not followed or if the work is carried out by non-professionally trained personnel.
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Lubrication System
Figure 1
P0035441 P0035462
Figure 2
P0035463
Engine Length (L)

D4/D6 900 mm (35 in)
D2, D3, D5, D7, D8, D9, D11, D12, D13, 280 mm (11 in)
D16
Transmission/drive Length (L)
IPS1 125 mm (5 in)
IPS10 100 mm (4 in)
IPS2/3/15/20/30 280 mm (11 in)
Reverse gear/S Drive: 100 mm (4 in)
DPH/DPI/DPS/DX 150 mm (6 in)
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Lubrication System
Figure 3
D2/D3/D5/D7/D8/D9/D11/D12/D13/D16 D4/D6
P0035464 P0035465
IPS1/IPS2/IPS3/15/20/30 IPS10
P0035466 P0035467
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Lubrication System
DPH, DPI
P0035468 P0035470
DPS, SX
P0035469
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Lubrication System
Reverse gear/S Drive:
P0035471 P0035473
Read the instructions before starting work. Check that all parts are included in the package. Illustrations can be
used for several different instructions. Therefore, objects in illustrations may differ from the installation in progress.
However, the main information is correct.
Designation Quantity Figure Position

Oil sampling bottle and postage packaging 5 1 1
Hose, reel, 100 m (328 ft) 1 1 2
Vacuum pump 1 1 3
Plastic bag 1 1 4
Not included in the kit intended for the U.S.
Installation instructions 1
General
Regular oil analyses provide improved insight into engine health.
Test reports are available on the Volvo Penta Partner Network within 48 hours of receiving the sample at the test
laboratory.
To obtain permission to access the report page, please contact Volvo Penta's sales office in each country.
NOTICE! The oil analysis is carried out to give recommendations. It can never replace service according to the
maintenance schedule.
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Fuel System
Sampling instructions
1 Start the engine and run until it reaches normal operating temperature.
2 Stop the engine and wait 15 minutes before taking the oil sample.
3 Cut off a suitable length of hose.
Use the oil dipstick as measurement of length (L). Mark the dipstick length on the hose. The length (+) is
needed to connect the hose to the pump. See figure 2
IMPORTANT!
Before cutting the hose, make sure that it fits in the tube of the dipstick.
4 Fit the hose into the upper part of the vacuum pump. Let the hose protrude approximately 40 mm (1.6").
5 Attach the sampling bottle to the pump.
6 Insert the sampling hose into the dipstick tube.
Locate the length marking (L) on the hose.
Take the sample halfway between the oil surface and the bottom of the oil sump.
Engine D4/D6 only: Insert the hose into the engine oil drain hose (A). Locate the length marking (L) on the
hose. Take the sample halfway between the oil surface and the bottom of the oil sump. See figure 3.
7 Pump up oil to flush the pipe.
Release the O-ring to break the vacuum and stop the oil flow.
Remove the sampling bottle and empty it. Ensure that the oil is collected in an environmentally friendly way.
8 Attach the sampling bottle to the pump and take an oil sample.
Fill the bottle to 80%. Remove the bottle and attach the cap immediately.
9 Send to the laboratory chosen by Volvo Penta to get your oil analysis report.
Clean the pump

• • Cut off the hose above the pump and pull the hose out of the pump from the opposite side to keep the pump
free of oil.
• Wipe the pump with a lint-free cloth or paper.
Apply a thin layer of silicone grease to both O-rings.
If necessary, use compressed air for cleaning.
• Assemble the vacuum pump and test its operation.
IMPORTANT:
Do not clean the pump with diesel, gasoline or detergents.
Additional orders through the spare parts system:

• Part number 21616535 (A kit that contains: Sampling bottles, vacuum pump, plastic hose, plastic tool bag
and instructions).
NOTICE! The plastic tool bag is not included in the version of the kit intended for the United States.
• Part number 21616560 (Hose reel, 100 meters, 328 feet).
NOTICE! For DPH/DPI drives, take the test as soon as possible after the boat lift. The DPH drive needs to be
tipped up.
NOTICE! See VPPN/Services/Volvo Penta oil analysis for oil wear limits.
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Fuel System
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Fuel System
Fuel System
General
The fuel system has a fine filter fitted to the engine as
standard. In addition, the installation often includes a
pre-filter as an option.
P0030204
Shown here are pre-filters sold by Volvo Penta. They

are available either as a single filter or dual changeover
filters.
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Fuel System
Fuel filter, Change

WARNING!
Fire hazard. When carrying out work on the fuel system
make sure the engine is cold. A fuel spill onto a hot
surface or an electrical component can cause a fire.
Store fuel soaked rags so that they cannot cause fire.
IMPORTANT!
Do not fill the new filter with fuel before installation.
There is a risk of system contamination that may cause
malfunction or damage
1 Remove the coupling piece.
P0026217
2 Remove the fuel filter.

3 Lubricate the sealing surface of the gasket on the
new filter with diesel oil.
4 Install the fuel filter. Tighten according to the
instructions on the filter.
5 Install the connector.
P0026218
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Fuel System
Fuel pre-filter
Volvo Penta fuel pre-filters are supplied in single and
double models.
Check
The double filter is fitted with a pressure gauge (A) that
indicates when it is time to replace the filter cartridges.
Replace the filter cartridges according to maintenance

schedule recommendations, or earlier if the pressure
gauge shows a pressure drop of 6–10 in. Hg at idle or
16–20 in. Hg at full rpm/engine load.
WARNING!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
P0029028
Draining
Place a container under the filter. Empty the water and
sediment through the plugs (B).
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Fuel System
Filter cartridge replacement

Double filter cartridges can be replaced while the
engine is running by shutting off the fuel flow to one
filter holder at a time.
Fuel flow is controlled by moving the handle (X) to the

following positions:
A Normal operating position (both filters connected).
B Left filter cartridge can be replaced.
C Right filter cartridge can be replaced.
D Both filters shut off.
P0029029
If the engine is stopped, begin by shutting the fuel
valves at the tank before replacing the filters. If the
engine is running, the fuel flow to the filter must be shut
off using the handle (X).
• Place a container under the filters and shut off the

filter for replacement.
• Undo the T-bolt (A) and remove the cover (B).
• Carefully remove the cartridge with a turning
movement.
• Empty the water and sediment through the drain
hole (C).
• Insert a new filter cartridge and fill the holder with
clean fuel.
• Replace the cover gasket and the T-bolt O-ring.
Moisten the gasket and the O-ring with fuel before
installing them.
P0029030
• Replace the cover and tighten by hand.
• Dry up any fuel spills.
• Replace the other filter in the same way.
• Open the fuel valves and put the lever in the normal
operating position. Check that there are no leaks.
• Repeat the procedure on the other filter.
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Fuel System
Fuel system, bleeding

CAUTION!
Never disconnect a fuel line or component after the fuel
pump to bleed. The fuel is under very high pressure
and can penetrate the skin.
1 Remove the rubber protective cover from the vent

screw. Fit a hose to the nipple and open the vent
screw.
P0026219
2 Pump the hand pump (1) until fuel free from air
bubbles comes out of the vent nipple. Keep
pumping at the same time as the vent nipple is
being closed. When all the air has been removed,
pumping becomes heavier.
3 Remove the hose and replace the rubber cap.
P0026220
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Exhaust System
Draining water from the fuel

1 Remove the connector to the sensor on the filter
(1).
2 Open the drain screw (2). Check that it clean fuel
is coming out.
3 Close the drain screw.
4 Re-connect the connector to the sensor.
NOTICE! Take care when closing the drain screw (2),

the threads are of plastic and easily broken. Screw until
the surfaces meet (slight resistance), then tighten a
further 1/4 turn, no more!
NOTICE! If water comes out of the fuel pre-filter, the

fuel tank must be drained and cleaned.
P0026313
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Exhaust System
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Exhaust System
Exhaust System
Exhaust hose
There may be different models available
IPS
Inspect the exhaust hose for wear and signs of
leakage. Replace the exhaust hose if it has cracks or
appears damaged.
The illustration shows an IPS installation. There is also

an exhaust hose on engines with reverse gear.
Stern drive
The drive has an exhaust bellows between the drive
and the engine that must be inspected.
Stern drive
There is an anode on the pipe after the exhaust
bellows.
Remove the cover (1).
Replace the anode (2).
Install the cover. Locking fluid must be applied to the
cover screws (1).
Tightening torque 24 Nm.
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Cooling System
Exhaust damper
Check the function of the IPS unit exhaust damper by
opening and closing it.
Lubricate its shaft at every service with propeller shaft
grease, (the grease nipple is on the side).
In position 1 the damper is open. In position 2 the

damper is closed.
NOTICE! Never start the engine with the damper

closed, pressure may force the hose to detach.
P0026314
Turbocharger, Inspection
Should be performed by an authorized workshop.
Please refer to the Workshop manual.
NOTICE! In the case of damage to the compressor/

turbine wheels, the complete turbocharger must be
replaced. We recommend this work be carried out by a
Volvo Penta workshop.
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Cooling System
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Cooling System
Cooling System
Coolant Level, Checking and
Topping Up
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.
NOTICE! Always use original parts and liquids

recommended by Volvo Penta.
Early engines have green coolant. Do NOT mix yellow
with green VCS!
NOTICE! Check the proportion of the anti-freeze

protection each year, if the coolant is not being
replaced.
1 Check the coolant level in the expansion tank.

There is an edge or marking in the expansion tank
indicating where the level must be when the
engine is cold.
2 Top up with coolant as necessary.
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Cooling System
Replacing coolant
1 Open the expansion tank cap.
2 Open all the drain points.
3 Drain the coolant from all the lowest points,.
NOTICE! If there is are heating elements connected to

the engine coolant system, these elements must be
drained in connection with replacement of the engine
coolant.
P0026223
To empty the cooling water, D6 engines.
P0026221
To empty the cooling water, D4/D6 engines
P0026222
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Cooling System
Filling an empty system

NOTICE! Mix the coolant in advance to ensure that the
cooling system is filled with the correct mixture,
(applies to concentrated coolant). Do not start the
engine until the system has been vented and is
completely filled.
NOTICE! If a heating unit is connected to the engine

cooling system, the heat control valve for the system
must be opened and the installation vented during
filling.
1 Check that all drain points are closed.

2 Fill with coolant until the level is above the MIN
mark in the expansion tank.
3 Start the engine when the cooling system has
been filled and vented.
4 Open any venting nipples shortly after starting, to
allow trapped air to escape.
5 Run the engine at idle for a couple of minutes.
Increase the engine speed to run at 1600-1700
rpm for about three minutes.
6 Switch the engine off and check the coolant level.
7 Start the engine. Start the engine again and run it
P0026315
until it reaches normal operating temperature
(when the thermostat opens). Switch off and
check the coolant level again after the engine has
cooled. Adjust as necessary.
NOTICE! The coolant contains corrosion protection

additives. Do not drain the system if the engine is to be
in storage for a longer period of time.
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Cooling System
Drive Belt, Replace

The following steps describe the removal/installation of
belts on an engine with double rive belts.
NOTICE! It is recommended that both belts are always

changed.
IMPORTANT:
Always change a belt that is oily, worn or damaged.
Removal
CAUTION!
Pinch hazard. Keep fingers clear.
1 Remove the protective cover.

2 Undo the bolts securing the outer belt’s tension
roller bracket.
3 Release the belt tension roller.
4 Remove the outer belt.
5 Turn the automatic belt tensioner to unload the

inner belt.
6 Remove the inner belt.
NOTICE! Check the operation of the pulleys/wheels

and their bearings. Replace the component in the
event of play/damage.
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Cooling System
Installation of the inner belt

1 Unload the automatic tensioner.
2 Install the belts.
3 Release the relief on the automatic belt tensioner.
4 Check that the belt is correctly aligned on all the
pulleys.
Installation of outer belt

1 Install the belts.
2 Tighten the tension roller’s square bunge.
Tightening torque 70 Nm. Keep it there.
3 Tighten the 2 bolts securing the belt tension roller.
Tightening torque 48 Nm.
4 Install the protective cover.
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Cooling System
Belt tightening, D4/D6 engines

1 D4
2 D4
3 D6
4 D6
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Cooling System
Seawater Pump, Impeller, Change
Removal
1 WARNING!
Risk of water entry. Close and drain the raw water
system before starting any work on the system.
2 Pull out the impeller.

3 Clean and inspect the seawater pump and
impeller cover. If it is worn, decide whether it
needs to be changed.
P0024418
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Cooling System
Installation
4 Lubricate the inside of the pump housing and the
new impeller with glycerin.
5 Press in the impeller with a rotating movement (as
in the illustration).
6 Install the cover; use a new gasket.
7 Open the cooling water cock.
8 Check that there is no leakage when the engine is
being started.
NOTICE! The impeller may be damaged if any types of

lubricant other than glycerin are used.
P0026224
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Cooling System
Seawater Filter, Check and Cleaning
If the waters where the boat is used contain a lot of

contamination, seaweed etc., the filter must be
checked more often than indicated in the maintenance
schedule. Otherwise there is a risk that the filter may
become blocked, resulting in engine overheating.
Removal
1 Close the sea cock in the boat.

2 Undo the clamp (1).
3 Remove the cover (2).
4 Lift out the insert (3) and clean it.
5 Install the filter in reverse order.
6 Open the sea cock and check that there are no
leaks when the engine is being started.
82 47707967 09-2022 © AB VOLVO PENTA

Cooling System
Cooling water intake, IPS

Check the cooling water cock for the IPS unit at every
service.
It must be possible to open and close the cock.

Lubricate as needed.
Check hoses and clamps.
P0026226
Cooling water intake

Check the cooling water cock operation at every
service.
It must be possible to open and close the cock.
Lubricate as needed.
Check hoses and clamps.
Clean the cooling water intake (outer grille) when the

boat is on dry land.
P0026225
47707967 09-2022 © AB VOLVO PENTA 83

Transmission
Anodes
Anodes are located on the heat exchanger and the

charge air cooler end walls (1). Replace anodes when
50% has been consumed.
On newer engines the end walls are plastic. These are
without anodes.
P0026227
NOTICE! Roughen new anodes with sandpaper to

activate them. Do not use a wire brush or grinding
abrasive during cleaning. This will impair the operation
of the galvanic anodes.
P0026228
84 47707967 09-2022 © AB VOLVO PENTA

Transmission
47707967 09-2022 © AB VOLVO PENTA 85

Transmission, IPS
Transmission
IPS
IPS
Component location
1 Oil filler
2 Oil dipstick
3 Oil filter
4 Oil drainage
5 Anode
86 47707967 09-2022 © AB VOLVO PENTA

Transmission, IPS
Clamping ring
Clean the surface between the clamping ring and
rubber seal from oxide and debris with lukewarm water,
a soapy water solution and a brush.
Suck out the water and dry off the space.
Lubricate with a suitable corrosion inhibitor afterwards.
(Generic illustration of an IPS unit. There may be
differences between different units)
Exhaust plate
Check the white plastic part of the IPS unit (colored
blue in the illustration) and its exhaust sealing. The
plastic part may not be painted. Clean with the boat out
of the water and check for any wear. Replace the
exhaust gasket if it is damaged.
NOTICE! Do not use a high pressure washer when

cleaning the exhaust plate.
IMPORTANT:
Be careful when cleaning with a high pressure washer.
Never point towards the propeller shaft seal or the
steering seals.
47707967 09-2022 © AB VOLVO PENTA 87

Transmission, IPS
Oil drain, IPS

In order to change the oil in the IPS unit the boat must
be lifted out of the water. Remove the drain plug at the
rear edge of the unit (1).
The IPS unit holds 14.7 liters (3.88 US Gallons)
Clean any dirt off the plug magnet before re-inserting it.
The tightening torque for the plug is 48 Nm.
P0026229
Oil filter, IPS

1 Remove the oil filter; be prepared to collect spilled
oil.
2 Lubricate the the surface of the gasket on the new
filter with a thin coating of oil.
3 Tighten the filter by hand until the surfaces meet
each other (and turning starts to become stiff),
then tighten a further 1/2 turn.
P0026238
88 47707967 09-2022 © AB VOLVO PENTA

Transmission, IPS
Oil filler, IPS
Fill up with the required amount of IPS oil (1). For

quantity and grade, see Specifications, page 35.
Check the level with the aid of the oil dipstick (2).
The oil dipstick must not be screwed down when

checking the level.
NOTICE! The oil dipstick is made of plastic; do not

overtighten
P0026230
IPS, oil level
Check the oil level using the dipstick.
NOTICE! The stern drive must be stopped for at least

12 hours before an accurate oil level check can be
made.
The level must be between the markings on the oil

dipstick.
The dipstick should not be screwed down when
checking the level.

overtighten.
P0026231
47707967 09-2022 © AB VOLVO PENTA 89

Transmission, IPS
Anode, exhaust outlet (IPS)

Replace the anode on the IPS unit when 50% has been
consumed. Clean any oxide off the new anode using
an emery cloth before installing it in order to activate it.
NOTICE! Do not use a wire brush or grinding abrasive

with metallic ingredients for cleaning the anode. This
will impair the galvanic function of the anode.
Tightening torque: 24 Nm
90 47707967 09-2022 © AB VOLVO PENTA

Transmission, IPS
Propeller
Checking for damage
Check the propeller blades.
If there is any damage it must be repaired or the
propeller replaced.
Should be performed by an authorized Volvo Penta
workshop, see workshop manual.
Lubricating the propeller shafts

Clean and grease the shafts with water-resistant
grease. This should be done annually, as propeller
removal will otherwise be difficult.
workshop, see workshop manual.
47707967 09-2022 © AB VOLVO PENTA 91

Transmission, IPS
Propeller shaft seals, replacement
Replacement of propeller shaft seals is a servicing item

on the IPS-unit but requires special tools and should
therefore be carried out by an authorized workshop.
Please refer to the Workshop manual.
Make a note of the maintenance schedule for your IPS.
Transmission: Oil strainer, inner

and outer
The oil strainer for the solenoids in the IPS drive gear
housing must be cleaned/changed according to the
intervals in the servicing schedule.
It is strongly recommended that this task is performed

at an authorized workshop.
For instructions, please refer to the workshop manual.
NOTICE! The servicing points differ between the older

A/B/C types and the newer types D/E/F.
P0033694
92 47707967 09-2022 © AB VOLVO PENTA

Transmission, IPS
Anodes
Volvo Penta's Active Corrosion Protection system

(ACP) protects IPS units against galvanic corrosion.
Replace anodes when 50% of the anode has been
consumed.
NOTICE! The anode on the IPS unit must always

remain in place, even if an ACP is connected.
If the boat is equipped with regular anodes, they must

be replaced when 50% has been consumed.
NOTICE! When regular anodes are fitted, there is

always 1 anode per drive.
Rub new anodes with an emery cloth to remove oxide

and activate their protection.
Do not use a wire brush or grinding abrasive. This will
impair the galvanic function of the anode.
NOTICE! Different materials on anodes four different

environments.
• Zinc for saltwater operations
P0028223
• Magnesium for freshwater operations
47707967 09-2022 © AB VOLVO PENTA 93

Transmission, IPS
Painting IPS Drives

Volvo Penta recommends that the drive units be
painted. This reduces fouling delivering lower fuel
consumption, and maximum speed will be retained
throughout the season. Painting also reduces the
anode consumption as there is less bare metal surface
in contact with the water.
All paints with anti-fouling agents are toxic and harmful

to the marine environment. If the waters where the boat
is sailed do not promote a high level of fouling or if the
boat is lifted out during the season to enable
mechanical cleaning, wherever possible, the use of
anti-fouling agents should be avoided.
Most countries have introduced legislation that
regulates the use of anti-fouling agents.
Check the legislation that applies where the boat is to

be used, and always comply with these regulations. In
many cases it is strictly forbidden to use anti-fouling
agents on leisure craft, e.g. in fresh water.
NOTICE! Tin-based agents (TBT) must never be used.
NOTICE! Do not use a copper-based paint on the IPS

unit.
Growth-inhibiting paint should be applied in three

stages:
• Clean the IPS drive with a suitable cleaning agent
before applying the primer (coating).
• Use a primer recommended by the manufacturer of
the anti-fouling paint and which is also suitable for
bronze alloys.
• Apply anti-fouling paint as the top coat. Follow the
manufacturer's recommendations in respect of the
number of coats of paint.
Do not paint the groove between the drive unit and the
hull.
Do not paint the white plastic section.
Do not paint the anode.
NOTICE! The paint must be dry before launching the

boat.
94 47707967 09-2022 © AB VOLVO PENTA

Transmission, Reversing gear
Reversing gear
Reversing gear, oil and filter change
The reverse gears are hydraulic and the lubrication

system is equipped with an oil filter and oil cooler.
The reverse gears to D4/D6:

HS45A Oil volume: 2.5 liters
HS63IV Oil volume: 4.3 liters
HS80A Oil volume: 5 liters
HS80IV Oil volume: 7 liters
HS80A-B Oil volume: 5.5 liters
HS80IV-B Oil volume: 7 liters
HS85IV Oil volume: 7 liters
NOTICE! The volumes that are specified exclude

hoses and the the oil cooler.
NOTICE! The illustration is generic; the design of the

reversing gear may differ.
P0026232
Changing the oil

1 Clean around the oil filler and the filter so there is
no risk of dirt entering.
2 Remove the oil filter.
3 Drain/draw out the oil from the designated drain
location (the plug at the bottom or through the
dipstick or oil filter hole).
4 Lubricate the gasket surface on the new filter with
a thin coating of oil.
5 Install the new oil filter.
6 Fill with new oil. Use the dipstick to check the oil
level is correct.
7 Start the engine and run it at 1500 rpm for a few
minutes.
8 Stop the engine and check the oil level again.
9 Top up as necessary.
NOTICE! Oil in accordance with

Specifications, page 35.
47707967 09-2022 © AB VOLVO PENTA 95

Checking the level and topping up

1 Unscrew the dipstick and wipe it off.
2 Put the dipstick back, without screwing it down.
3 Lift the dipstick out again and check the level.
4 Top up with oil if necessary.
NOTICE! Never overfill the reversing gear with oil. The

level must be inside the marked area on the oil dipstick.
96 47707967 09-2022 © AB VOLVO PENTA

Grease-lubricated shaft
1 Check that there is grease in the grease cup.
2 Lubricate the shaft at each service.
3 Check the shaft bushing seal. If there is any
leakage, the seal must be replaced.
P0026233
Water-lubricated shaft
On launching, inspect the rubber stuffing box on the
propeller shaft to ensure it is sealing, and that there are
no cracks. Check during the season for leakage of
water into the boat through the stuffing box; if so, the
rubber stuffing box must be changed.
The rubber sleeve on the propeller shaft must be

vented when the boat is launched. The sleeve is
vented by squeezing the sleeve mouth (where the
shaft emerges) together while at the same time
pressing the shaft lightly downwards.
It is recommended to press in 1/4 teaspoon of water
resistant grease on launching, to lubricate the lead-
through on starting.
P0026234
47707967 09-2022 © AB VOLVO PENTA 97

Electric rudder actuator

Check the oil level with the aid of the dipstick on the
side of the rudder actuator.
The oil dipstick must not be screwed down when
checking the level. The level must be between the
markings on the oil dipstick.

overtighten.
P0026316
Changing the oil in the rudder actuator

Oil change intervals according to the maintenance
schedule. When changing the oil, suction it off through
the dipstick hole.
Quantity approx 4.2 liters.
Also check that the bolted joint is secured and the

linkage between the actuator and rudders is not
binding.
P0026317
98 47707967 09-2022 © AB VOLVO PENTA

Transmission, Sterndrive
Sterndrive
Stern drive
The stern drive is protected against galvanic corrosion
by several layers of paint, sacrificial anodes and
ground braids. The ground braids ensure an electrical
connection between the different drive components. A
loose ground braid connection can rapidly lead to
corrosion damage to individual components. For this
reason the ground braids/wiring harness must be
checked to ensure that they are securely fastened.
External stern drive service points.

1 U-joint bellows
2 Oil filler (under the cover)
3 Anode
4 Anode
5 Exhaust bellows
6 Oil drainage
47707967 09-2022 © AB VOLVO PENTA 99

Service points inside the transom shield, Power

trim.
1 Exhaust bellows
2 Coolant hose
3 Hydraulic steering
4 Power trim Oil container
5 Anode exhaust pipe (late model)
6 Shaft splines
100 47707967 09-2022 © AB VOLVO PENTA

Valve block, oil filter, change

1 Remove the return hose and pressure hose from
the servo pump and let the oil run out,
Allow the hoses to be disconnected.
P0026235
2 Remove the oil filter with bypass cover from the

hydraulic valve unit and let the oil run off.
Replace the oil filter and bypass cover.
Tightening torque: 34 Nm
P0015484
3 Put the hoses on the the pump.
P0015485
47707967 09-2022 © AB VOLVO PENTA 101

4 Fill the power steering fluid container.
P0015486
5 Move the throttle control to the neutral position.

Place the EVC in Venting position, this will
prevent an EVC error during venting.
2a: EVC-C3
2b: EVC-D
P0015487
Refer to following chapter for a more detailed

description of venting: Transmission, page 102.
DPI
Aquamatic with electronic steering

To ensure satisfactory steering system, venting at the first start is required.
WARNING!
Make sure that no person is near the drive while the steering wheel is rotated.
1. Move control to 2. Turn on the ignition. 3. THROTTLE ONLY: 4. Calibration mode

neutral. press and hold for at is activated.
least 5 seconds.
102 47707967 09-2022 © AB VOLVO PENTA

5. Calibration Mode 1.0. 6. Turn steering wheel 7. First turn Starboard to 8. Ignition must be turned
until buzzer alarms. end position, followed off for at least 15 seconds to
by Port to end position. confirm the calibration.
Repeat end to end
positions10 times.
Sterdrive, hydraulic fluids
Check the oil level in the drive hydraulics at each

service interval.
The level must be between the markings on the vessel.
47707967 09-2022 © AB VOLVO PENTA 103

Sterndrive, oil level

Remove the the cover on the stern drive.
When checking the oil level, trim the drive up to approx.

37 degrees.
The neck of the oil filler must be horizontal.
Remove the oil filler plug.

The oil level should be 40 mm below the oil plug
contact surface (X) as illustrated.
P0020733
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47707967 09-2022 © AB VOLVO PENTA 105

DPH-A/B/C/D, DPR-A/B/C/D
When checking the oil level the drive is trimmed up to

approx 37 degrees.
The oil level should be below contact surface of the oil
plug as illustrated.
106 47707967 09-2022 © AB VOLVO PENTA

Sterndrive, Draining
Empty the stern drive oil as illustrated.
Start by removing the top cover.
Remove the vent plug.
P0026318
47707967 09-2022 © AB VOLVO PENTA 107

Place a container under the stern drive to collect the

oil . See workshop handbook to remove the propellers
and release the oil drain plug located behind.
NOTICE! At the same time, take the opportunity to

check the color of the fluid during replacement. If the oil
is light/cloudy, water has entered and the shaft seal
and this must be changed.
P0026319
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Sterndrive, Oil Filling

IMPORTANT!
The oil level varies depending on the generation of the
stern drive, (A).
The recommended gear lubricant can vary depending
on the gear ratio of the stem drive (B).
The oil filler plug (C) must be labeled “75W-140” (D)
when the higher viscosity of the gear lubricant is to be
used.
P0020728
1 Trim up the stem drive to ~37°.

P0020729
2 DPH-A/B/C/D, DPR-A/B/C/D
Fill slowly with oil up until the oil filler duct is
completely filled.
Fit the oil filler plug.
P0020730
47707967 09-2022 © AB VOLVO PENTA 109

3 Lower the stem drive and trim it up again to ~37°

to eliminate any air pockets.
P0020731
4 Remove the oil filler plug and check the oil level.
Top up with oil if the oil filler duct is not completely
filled.
Fit the oil filler plug.
P0020730
5 DPH-D1 →
Remove the vent plug.
P0026318
6 Fill with oil.

The oil level should be 40 mm below the oil plug
contact surface (X) as illustrated.
Fit the vent plug and the oil filler plug.
110 47707967 09-2022 © AB VOLVO PENTA

Sterndrive bellows
Inspect the drive gear bellows with the boat out of the
water. Replace within the recommended interval in
accordance with the servicing schedule.
1 Inspect the outside of the bellows for cracks.
2 Check for wear on the inside of the rubber once
the drive gear is removed.
3 When replacing bellows, check that the drainage
holes are pointing downwards and the clamps are
in the correct position in the groove in the rubber
bellows.
Do not paint the drive bellows.

Paint on the rubber will dry out and reduce the service
life. It will also be more difficult to check the bellows for
cracks if it is painted.
47707967 09-2022 © AB VOLVO PENTA 111

Propeller
Checking for damage

Check the blades on the propellers for damage.
If these are damaged, they must be fixed or replaced.
Any replacement or repair work should be performed
by an authorized Volvo Penta workshop; see workshop
manual.
Lubricating the propeller shafts

Clean and grease the shafts with water-resistant
grease. This should be done annually, as propeller
removal will otherwise be difficult.
workshop; see workshop manual.
112 47707967 09-2022 © AB VOLVO PENTA

Active corrosion protection, ACP

Accessories together with AQ units.
ACP protects AQ units against corrosion.
Active corrosive protection is only active if there is
power.
For this reason, we recommend that shore power is
always connected when the boat is stationary.
ACP may only exist together with zinc anodes.
WARNING!
Warning when cleaning.

May only be cleaned with a plastic scraper.
May be high-pressure washed; see Cleaning engine
and transmission, page 121.
Marked areas must not be painted over.
P0026548
Checking Protective Anodes
Check the anodes every time the boat is out of the

water. Replace anodes when 50% of the anode has
been consumed.
When the boat is out of the water, corrosion protection

deteriorates due to anode oxidization. Even new
anodes may have some surface oxidation. Always
clean and polish them with an emery cloth before
launching in order to have full protection.
NOTICE! DPR and twin installations also have anodes

on the parallel rods.
Replacement of anodes
1 Remove the anode retaining bolts.
2 Clean the contact surfaces on the new anode and
the corresponding surface on the drive.
3 Install the new anodes and tighten their screws so
that they make good contact with the underlying
metal.
NOTICE! Do not use a wire brush or grinding abrasive

with metallic ingredients for cleaning the anode. This
will impair the galvanic function of the anode.
47707967 09-2022 © AB VOLVO PENTA 113

NOTICE! If, for the most part, the boat is used in salt
water, all the anodes must be of zinc or aluminum. If the
boat is mostly used in fresh water, all the anodes must
be of magnesium.
114 47707967 09-2022 © AB VOLVO PENTA

Long-Term Storage
Painting the Drive

WARNING!
Read and carefully follow the instructions and

warnings on the packaging.
Remove all loose paint and corrosion residue by
blasting or with sandpaper.
If blasting is used, the blasting agent should be
aluminum oxide with a particle size of between 0.2 and
0.7 mm.
If sandpaper is used, it must be coated with aluminum
oxide.
Sand the painted surfaces and the damaged/corroded
raw aluminum surfaces to be touched up.
Then clean using clean water.
WARNING!
Do not use steel wool. Small pieces of steel will

become embedded in the aluminum and will cause
severe corrosion damage.
WARNING!
Do not use emery cloth. Small pieces of iron oxide

which are used in the emery cloth will become
embedded in the aluminum and will cause severe
corrosion damage.
When the primer coating is thin or the surface is

unpainted, it must first be coated with primer, part #
1141562.
Drying time 8-12 hours.
Then apply a final coat.

The spare parts catalog and the “Volvo Penta
accessories” catalog specify the part numbers for
surface treatment products.
Also apply anti-fouling.
NOTICE! Use a locally recommended anti-fouling

paint on the drive gear.
P0029743
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Long-Term Storage
116 47707967 09-2022 © AB VOLVO PENTA

Long-Term Storage
Long-Term Storage
If the boat is not going to be used for two months or more, it is important to reduce the risk of damage to the engine
and other equipment. The suggestions below include measures to prevent freeze-bursting and reduce the
formation of condensation, mold and corrosion.
IMPORTANT:
When cleaning with a high pressure washer, make sure to never aim the water jet at seals, rubber hoses or
electrical components.
Before storage
• The fuel system must be protected during storage
to prevent internal oxidation and corrosion.
• Start and run the engine with FAME-free fuel. Run
the engine for at least 10 minutes to allow the fuel
to reach all parts of the injection system. The fuel
may be fed from a separate tank if preferred.
• If B0 fuel is not available, fuel additives with anti-
corrosion and anti-oxidation properties may be
mixed in the fuel to protect the fuel system during
storage.
• Engines that use diesel fuel with a FAME content
greater than 10%, (even if additives are used) must
not be placed in long-term storage.
NOTICE! Attach a note on the engine/filters with the date FAME = Biodiesel
and type of oil that has been used so it is easier to B0 = Diesel with 0% FAME
remember what has been carried out when it is time to B10 = Diesel with 10% FAME
launch.
• Drain water from the pre-filter to reduce the risk of
bacterial growth.
• Drain and clean the fuel tank.
• Fill the fuel tank with fuel to avoid condensation
during storage. Use the recommended B0 fuel.
• Check that the coolant offers adequate protection
against freezing. Check the level and top up as
necessary.
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Long-Term Storage
• Drain all the remaining seawater from the cooling

system, (heat exchanger, charge air cooler,
impeller pump, hoses containing sea water).
• Remove the impeller from the seawater pump.
Store the impeller in a sealed plastic bag and keep
it cool.
• Disconnect the battery cables; clean and charge
the batteries.
An insufficiently charged battery can freeze and
burst if stored at freezing temperatures.
• For cleaning the engine and transmission, see the
next section.
• Touch up any paint damage with Volvo Penta
original paint or paint of the same quality.
• If necessary, cover the engine, air intake and
exhaust pipe.
• Always ensure good ventilation in the engine
compartment in order to prevent the formation of
mold and corrosion (if possible, leave hatches
open).
After storage
• Replace filters before starting the engine. Keep
extra filters available as FAME may cause
microbial growth that blocks the fuel filter.
118 47707967 09-2022 © AB VOLVO PENTA

Long-Term Storage
Storage instruction for long-term

storage of new engine
Applies to installed and non-installed

engines
The engines must be laid up in a warm,

temperature-controlled store.
The temperature should be between +5°C and
+30°C.
Storage outdoors is strictly prohibited.
Humidity should be below 40%.
We recommend that you:
– Unpack the engine, remove the plastic wrap.
– Use the plastic bag as dust protection; leave it
loose for good ventilation.
– Do not use wax as protection in case the engine
must be started during storage.
If the engine must be stored for more than 8

months
Before storage
Make sure the engine cooling system is filled with
glycol.
Make sure the engine lubrication system is filled with
oil.
Pump the coolant through the seawater cooling
system. (Marine engines only)
Seal all open connections.
Remove the battery cables from the battery.
Empty the AdBlue®/DEF tank if it is filled and clean
it.
Attach a tag into the engine with information about
the date, the product's part number, type of oil used
and sign it.
During storage
The engine must be cranked 2.5 turns every 8th
month.
If the engine can be started, run it until warm.
Check that humidity is below 40%.
Check that the temperature in the storage area is
between +5°C and +30°C.
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Long-Term Storage
Before the engine enters service.

Uncover the engine or vacuum the system until dry.
This is in order to prevent remaining glycol mixture
from contaminating the environment.
Hand the glycol mixture to a waste management
facility as hazardous waste.
Clean the engine as necessary.
Check:
– Drive belts
– Hoses
– Clamps
Check the oil level in the engine and top off as
necessary.
Make sure the coolant has adequate antifreeze
properties; top off as necessary.
Should be replaced:
– Fuel filter
– Air filter
– AdBlue®/DEF filter
– Air filter AdBlue®/DEF tank
– Fill the AdBlue®/DEF tank
– Seawater pump impeller (Marine engines only)
– Anodes for the seawater system. (Marine engines
only)
Start the engine and let it idle a while without a load.
Check that there are no oil, fuel or coolant leaks.
Run the engine until warm.
Change the engine oil and oil filter.
Checklist, long term storage

Date Product part number Type of conservation Signature and date of checks
Month Checks during storage

8,
16,
24,
32,
40,
120 47707967 09-2022 © AB VOLVO PENTA

Long-Term Storage
Cleaning engine and transmission
Including the engine encapsulation and all

hatches
• A clean engine compartment minimizes the risk of
overheating and wear damage.
• Prior to every engine compartment wash, a visual
inspection must be carried out to identify any fluid or
exhaust leakages.
• Following each wash, all hoses and bellows must be
inspected visually to identify any leakages, cracks or
chafing.
• Following each wash, electrical harnesses must be
visually inspected to identify any damage to
insulation, cable jackets or clamping.
• Battery, alternator, power steering unit and starter
motor cables must be inspected extra carefully.
• Any damage to hoses, bellows, grommets or
electrical harnesses must be reported immediately.
Important!
• When cleaning, always use mild detergents/
solvents.
• When cleaning the engine and engine
compartment, the alternator, idler pulley, belt
tensioner, power steering unit and all electrical
components must be covered with plastic or similar
so that detergent/solvents do not get into the parts
• Where fitted, the AC compressor must also be
protected with plastic or similar.
• When cleaning air coolers, they should be vacuum
cleaned first before flushing with warm water from
the inside out.
• Do not use a power washer on the air cooler.
• Clean the outside with a sponge/brush.
• Then flush with lukewarm water.
• When pressure washing and steam cleaning, water
pressure may not exceed 80-100 bar at the nozzle.
Maintain a distance of 100-150 mm; use a fan spray
nozzle.
• It is not permitted to came jets of water from the
pressure washer directly onto the alternator. The
electrical regulator, rectifiers, power steering units,
bellows and mechanical parts (bearings) may be
damaged and lead to serious consequential
damage.
NOTICE! If the generator is exposed to water, it must

be dried; see drying.
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Long-Term Storage
• Wash using a flat fan nozzle when cleaning sound

absorbent.
• To maintain the fire prevention and sound
dampening qualities of the absorbent as per the
sound certificate, no damage to the absorbent may
be repaired with the aid of patches or the puzzle
principal i.e. by covering any damage with new
absorbent (patch). Accordingly, in the case of major
damage or where fluid has seeped into the
absorbent (deep tears, tears wider than the width of
tape; holes or cracked edges), the entire damaged
unit must be replaced.
• Tears that can be covered widthwise by tape, must
be repaired using approved aluminum tape.
• After the wash, check that no small rocks or other
debris has adhered to the belts and are able to
penetrate them when the engine is started.
Drying the alternator

• Blow the water away from the alternator using
compressed air.
• Check that the alternator charges.
122 47707967 09-2022 © AB VOLVO PENTA

Long-Term Storage
Cold Weather Precautions
IMPORTANT:
Coolant of a suitable chemical composition must be
used all year round to protect the engine against
internal corrosion, cavitation and freeze bursting.
This even applies when there is no risk for freeze
damage, to make sure the engine always has a
complete corrosion protection.
• Drain the sea water from the heat exchanger and the
charge air cooler and remove the impeller pump
cover.
• Check that all the water drains out, any remaining
water could freeze and cause freeze bursting.
The risk of freeze bursting can be reduced by running

the engine when on land with a mixture of 40% coolant
and 60% fresh water through the sea water system
(connected at the sea water intake) before the engine
is switched off.
Use a container to collect the glycol mixture from the
exhaust outlet and hand it in to a recycling station.
Pump out the bilge water and dry off the space in the
engine compartment. Ensure good ventilation during
winter storage to prevent the formation of mold/
corrosion.
NOTICE! Once the engine is drained of seawater/salt

water, check that it does not get onto the alternator, fuel
pump or other parts susceptible to corrosion. If it is not
possible to avoid this, carefully flush with fresh water
and make sure it is properly dried up afterwards.
47707967 09-2022 © AB VOLVO PENTA 123

Long-Term Storage
Charge air cooler

Drain the seawater through the drain on the side of the
charge air cooler, on the coolant pipe.
P0026320
The heat exchanger

Drain the seawater through the drain at the side of the
heat exchanger. Connect a hose to the nipple, to make
it easier to lead the water to a container.
P0026237
124 47707967 09-2022 © AB VOLVO PENTA

Long-Term Storage
Checklist
Suggestions for the checklist in addition to the regular
service points:
Checks/actions when taking the boat out of the

water
• Check for leakage: fuel/water/exhaust.
• Check hose clamps and bellows.
• Check cable connections.
• Inspect through-hull fittings/cocks.
• Check the cooling water cock: opening/closing.
Replace if stuck.
• Clean off fouling growth (drive/hull/propellers).
• Clean the battery terminals; remove oxide.
Check the electrolyte level.
• Clean the engine and engine compartment.
• Clean the fuel tank.
• Drain/replace the fuel pre-filter.
• Functional check of other electrical systems.
• Check the rudder, drive and propeller(s).
Start the engine every six months
If the boat will be out of the water for 6-8 months or
more, the engine must be started and warmed up every
six months as follows:
• Check the engine oil level.
• Check the oil level in the drive or reverse gear.
• Check the coolant level.
• Connect the battery cables to the batteries (fully
charged).
• Take the impeller out of the seawater pump, or
connect cooling water via a hose to the intake.
• Start the engine and run it for 2-3 minutes with the
gearshift in the neutral position.
• Switch off the engine.
• Rotate the stern drive or reverser output shafts by
hand for 2-3 turns.
• Detach the battery cables.
• Check the engine compartment for any
condensation.
• Ensure good ventilation.
47707967 09-2022 © AB VOLVO PENTA 125

Long-Term Storage
Battery, Maintenance
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the batteries.
WARNING!
Battery electrolyte is a corrosive acid and should be
handled with care. If you spill or splash electrolyte on
any part of the body, immediately flush the exposed
area with liberal amounts of water and seek medical
attention as soon as possible.
WARNING!
Ventilate the engine compartment before working on
batteries or battery connections.
IMPORTANT:
Batteries can be damaged if they are left discharged,
and can also freeze and burst easier in cold weather. If
the engine is not going to be used for a longer period of
time, the batteries should be fully charged, trickle
charged if possible.
Care
It is important always to follow the battery
manufacturer's recommendations and instructions
when replacing and charging batteries. Instructions for
maintenance and charging may vary depending on
battery type.
Modern batteries are usually maintenance free, but
there are some recommended measures to avoid
accidents and increase battery service life:
• Keep the batteries clean and dry. Contamination
and oxide on the batteries and battery terminals can
cause stray currents, voltage drop and discharge,
especially in damp weather.
• Remove oxidation from the battery poles and
terminals using a brass brush.
• Tighten the terminals securely and grease them with
terminal grease or petroleum jelly. Loose battery
connections can cause damage to the engine
electrical system.
• Charge the batteries regularly. Batteries kept at full
charge enjoy maximum service life. The easiest way
to check whether a battery needs charging is to use
a volt meter.
126 47707967 09-2022 © AB VOLVO PENTA

Long-Term Storage
Battery replacement
IMPORTANT:
Make sure that the new battery fulfills the specifications
in Technical Data. Read the information supplied with
the battery before you begin the installation.
IMPORTANT:
Do not disconnect the batteries with the engine
running.
Sensitive electrical components can be immediately
damaged.
WARNING!
Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.
Disconnection (A)
• Remove the negative (-) cable (black).
• Remove the positive (+) cable (red).
Remove the battery.
Connection (B)
Put the new battery in place.

• Attach the positive cable (red) to the battery's
positive terminal. Tightening torque: 6 Nm.
• Attach the negative cable (black) to the battery's
negative terminal. Tightening torque: 6 Nm.
NOTICE! Hand in the old battery to a waste

management facility.
P0028239
47707967 09-2022 © AB VOLVO PENTA 127

Index
A P
Air Filter.................................................................... 48 Painting IPS Drives.................................................. 94
Anode, exhaust outlet (IPS)..................................... 90 Painting the Drive................................................... 115
Anodes............................................................... 84, 93 Preventive repair ..................................................... 16
B Propeller........................................................... 91, 112
Battery, Maintenance.............................................. 126 Propeller shaft seals, replacement........................... 92
C R
Check software status.............................................. 48 Reversing gear......................................................... 95
Checking Protective Anodes.................................. 113 Reversing gear, oil and filter change........................ 95
Checklist................................................................. 125 S
Chemical products.................................................... 27 Safety Information...................................................... 5
Cleaning engine and transmission......................... 121 Seawater Filter, Check and Cleaning....................... 82
Cold Weather Precautions..................................... 123 Seawater Pump, Impeller, Change........................... 80
Component location................................................. 41 Service Protocol....................................................... 15
Compressor oil, Replace.......................................... 50 Spare parts - safety.................................................... 7
Compressor, oil level................................................ 50 Special Tools............................................................ 29
Coolant Level, Checking and Topping Up................ 74 Specifications..................................................... 31, 35
Cooling System........................................................ 74 Sterdrive, hydraulic fluids....................................... 103
Crankcase Ventilation, Filter Change....................... 49 Sterndrive bellows................................................... 111
D Sterndrive, Draining................................................ 107
Drive Belt, Replace................................................... 77 Sterndrive, Oil Filling.............................................. 109
Sterndrive, oil level................................................. 104
E Storage instruction for long-term storage of new
Engine...................................................................... 40 engine..................................................................... 119
Engine Decals.......................................................... 31
Engine Oil, Level Check........................................... 52 T
Engine oil, Replace.................................................. 54 Transmission Decals................................................ 32
Exhaust hose............................................................ 71 Transmission: Oil strainer, inner and outer............... 92
Exhaust System....................................................... 71 Turbocharger, Inspection.......................................... 72
F V
Fuel filter, Change.................................................... 65 Valve block, oil filter, change.................................. 101
Fuel pre-filter............................................................ 66 W
Fuel System............................................................. 64 When you work with Chemicals, Fuel and
Fuel system, bleeding.............................................. 68 Lubrication Oil, Change............................................ 52
G
General advice for electronic protection................... 47
General Information.................................................. 14
General inspection................................................... 45
General Tightening Torques..................................... 34
Genuine Volvo Penta Parts...................................... 23
I
Illustrations............................................................... 25
IPS, oil level.............................................................. 89
L
Long-Term Storage................................................. 117
Lubrication System................................................... 52
M
Maintenance Schedule............................................. 44
O
Oil drain, IPS............................................................ 88
Oil filler, IPS.............................................................. 89
Oil filter, IPS.............................................................. 88
Oil filter, Replace...................................................... 55
Oil topping up and level check................................. 56
Other Special Equipment......................................... 29
47707967 09-2022 © AB VOLVO PENTA 129

47707967 English
AB Volvo Penta
SE-405 08 Göteborg, Sweden
www.volvopenta.com

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service and maintenance

47707967 09-2022 © AB VOLVO PENTA 1

2 47707967 09-2022 © AB VOLVO PENTA

4 47707967 09-2022 © AB VOLVO PENTA

Safety texts have the following order of priority:

NOTICE! Used to draw attention to important information that facilitates work or

47707967 09-2022 © AB VOLVO PENTA 5

Most chemicals such as engine and transmission oils,

Carefully read the instructions on the product

Manage used and leftover chemicals in the prescribed

Personal safety equipment

Some examples are ear protection, eye and face

Protect your eyes

Always wear safety glasses if there is a risk of

Protect your skin

Avoid getting oil on your skin! Prolonged or repeated

Use protective gloves and avoid oil-soaked clothes

6 47707967 09-2022 © AB VOLVO PENTA

All fuels – as well as many lubricants and chemicals –

Ensure that the workplace is well ventilated and take

Spare parts - safety

Components in fuel systems and electrical systems on

Used oils, filters and chemicals etc.

Oil-soaked rags can spontaneously ignite under

Prevent start of the engine

47707967 09-2022 © AB VOLVO PENTA 7

Ventilation when running the engine

The engine must not be operated in areas where there

Rotating parts and hot surfaces

Be careful to avoid hot surfaces (exhaust pipes,

Information on the engine

8 47707967 09-2022 © AB VOLVO PENTA

Prohibition on use of start spray

Before start of engine

Before any work on the electrical system

Avoid damage to the engine control

Before any work on the cooling system

47707967 09-2022 © AB VOLVO PENTA 9

Risk of water penetration/sinking

Hot coolant under pressure

Open the filler cap slowly, and release the pressure in

Hot oil under pressure

At any leak detection on the fuel system

Handling of fuel pipes

Before any work on the fuel system —

10 47707967 09-2022 © AB VOLVO PENTA

Safe handling of batteries

A spark caused by an incorrectly connected battery

Do not touch the connections during a starting attempt.

Correct polarity of the batteries

Risks of electrolyte in batteries

Rinse immediately with copious amounts of water if the

If it comes electrolyte to unprotected skin, wash

After finished work with the engine

Cleaning the engine and components

Cleanliness for sensitive components

47707967 09-2022 © AB VOLVO PENTA 11

Lifting the engine

Proper lifting equipment