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Volvo Penta
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5.0 GL
Volvo Penta 5.0 GL User Manual
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Workshop Manual
Engine
C
2(0)
5.0 GL
5.7 Gi
5.0/5.7 GXi
5.0/5.7 OSi, 5.7 OSXi
2
Table of Contents
General Information
7
Table of Contents
7
Tuning the Engine
9
Intake Manifold Vacuum Testing
12
Gasoline Requirements
14
Gasoline Containing Alcohol
15
Crankcase Oil
15
Oil Filter
17
Power Steering
17
Power Trim/Tilt Fluid Level
17
Off-Season Storage
18
Preparation for Boating after Storage
20
Engine Break-In
21
Submerged Engine or Water Ingestion in Cylinders
22
20-Hour Check
23
Positive Closed Ventilation System
24
Troubleshooting - System Isolation
25
Engine will Not Crank
26
Engine Troubleshooting Guides
26
Engine will Not Crank
27
Engine Runs Rough
28
Hard Starting - Cold Engine
28
Hard Starting - Hot Engine
28
Engine Noises and Vibrations
29
Engine dies out
30
Engine Overheats - Check
30
Defective Engine Lubricating System
31
Low Battery Voltage after Short Storage
32
Engine - 5.0 & 5.7 Litre
33
General Description
34
Accessories
35
Tools and Shop Equipment
35
Cleaning
36
Draining the Engine
37
Engine Lubrication
40
Exhaust Manifold
41
Starter
43
Intake Manifold
45
Remove Distributor, Gi and Gxi Models
46
Disassemble Intake Manifold (Gi, Gxi, Osi, & Osxi)
48
Assemble Intake Manifold
51
Intake Manifold Installation
51
Distributor Installation
53
Rocker Arm Cover
58
Valve Train
58
Valve Lifters and Guides Clean and Inspect
61
Valve Lifter Installation
62
Valve Lifter Pushrod Guides
62
Valve Push Rod
62
Install Rocker Arm Assemblies
63
Valve Lash Adjustment
63
Cylinder Head
64
Valve Rocker Arm Cover Installation
64
Cylinder Head Disassemble and Recondition
66
Cylinder Head Clean and Inspect
67
Valve Spring Straightness
68
Valve Stems
69
Valve Guide Reaming and Seat Grinding
70
Valve Rocker Arm Stud Removal
72
Valve Rocker Arm Stud Installation
73
Cylinder Head Assemble
74
Install Oil Seal
74
Oil Pan and Oil Pump
78
Oil Pan Clean and Inspect
79
Oil Pump Disassemble
81
Oil Pump Clean and Inspect
82
Water Pump
88
Water Pump Installation
92
Crankshaft Balancer
93
Crankshaft Balancer Inspect
94
Crankshaft Balancer Installation
94
Engine Front Cover
96
Engine Front Cover Installation
98
Timing Chain and Sprocket
98
Camshaft
103
Camshaft Bearings
105
Piston, Connecting Rod, and Bearings
109
Piston and Connecting Rod Disassemble
111
Clean and Inspect
112
Piston Selection
115
Engine Coupler
120
Flywheel
123
Crankshaft Rear Oil Seal and Housing
124
Crankshaft
127
Crankshaft and Bearings Clean and Inspect
128
Bearing Clearance Measuring Procedures
131
Micrometer Method for Crankshaft Bearings
131
Engine Block Plug
137
Recondition Engine Block
137
Engine Block Clean and Inspect
140
Cylinder Boring and Honing
141
Boring Procedure
142
Engine Specifications 5.0 Litre
143
Engine Specifications 5.7 Litre
147
Fastener Tightening Specifications
151
Sealants, Adhesives and Lubricants
154
Tune up Specifications
154
Special Tools
156
Marine Products and Safety of People Who Use Them
162
Sterndrive Shift System
163
Sterndrive Throttle Control System
164
Sterndrive Steering System
165
Marine Products and Safety of People Who Fix Them
171
Handling Lead Acid Batteries
172
Gasoline! Handle with Care
173
Hazardous Products
174
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Volvo Penta 5.0 GL Specifications
General
Engine Type
V8
Fuel Type
Gasoline
Aspiration
Naturally Aspirated
Fuel System
Carbureted
Horsepower
220 hp
Displacement
5.0 liters
Max RPM
4600-5000 RPM
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