This repair and service manual covers Volvo Penta Stern Drives including 30GS 3.0L in-line 4-cylinder (135 HP), 43GL 4.3L V6 (160 HP), 43GI 4.3L V6 (180 HP), 43GXI 4.3L V6 (210 HP), 50GL 5.0L V8 (220 HP), 50GI 5.0L V8 (250 HP), 50GXI 5.0L V8 (270 HP), 57GS 5.7L V8 (225 HP), 57GS 5.7L V8 (250 HP), 57GSI 5.7L V8 (280 HP), 57GXI 5.7L V8 (320 HP), 81GI 8.1L V8 (375 HP), 81GXI 8.1L V8 (420 HP), DPX375 8.1L V8 (375 HP), and DPX420 8.1L V8 (420 HP), 2001 to 2004. Clymer marine repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from routine maintenance and troubleshooting, to complete teardown & rebuild. Table of Contents: QUICK REFERENCE DATA CHAPTER ONE / GENERAL INFORMATION Manual organization / Warnings, cautions and notes / Safety / Model identification / Engine operation / Fasteners / Shop supplies / Galvanic corrosion / Propellers / Basic tools / Special tools / Precision measuring tools / Electrical component replacement / Electrical system fundamentals / Basic mechanical skills / Specifications. CHAPTER TWO / TROUBLESHOOTING Electrical component replacement / Preliminary inspection / Electric starting system / Charging system / Ignition system / Basic fuel system troubleshooting / Carburetor fuel system / Electronic fuel injection (EFI) system / Diagnostic trouble codes / Power steering system / Power trim electrical system troubleshooting / Power trim hydraulic system troubleshooting / Cooling system troubleshooting / Warning system / Engine troubleshooting / Drive system / Specifications. CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP Before each use / After each use / Lubrication / Fuel system maintenance / Engine coolant / Tune-up / Submersion / Specifications. CHAPTER FOUR / LAY-UP, WINTERIZING AND FITTING OUT Lay-up / Winterizing / Fitting out CHAPTER FIVE / ADJUSTMENTS Carburetor adjustment / Ignition timing adjustment / Shift cable and linkage adjustment / Throttle cable adjustment / Trim position sender and trim limit control module adjustment / Specifications. CHAPTER SIX / ENGINE Engine operation / Special tools / Replacement parts / Special service precautions / Engine removal/installation / Engine alignment / Rocker arm cover / Valve adjustment / Placing the No. 1 piston at TDC (firing position) / Lifter cover / Camshaft lobe lift measurement / Cylinder head / Rocker arm and pushrod / Flywheel housing / Drive coupler / Drive plate / Flywheel / Flywheel pilot bearing / Output drive shaft, seals and bearings / Oil pan / Oil pump / Harmonic balancer / Timing gear/chain cover / Timing chain and sprockets / Balance shaft / Camshaft and lifters / Piston and connecting rod / Rear main seal and rear main seal carrier / Crankshaft / Break-in procedure / Specifications. CHAPTER SEVEN / FUEL SYSTEMS Fuel system service / Mechanical fuel pump / Low-pressure electric fuel pump / Carburetor / Electronic fuel injection (EFI) / Intake manifold / Specifications. CHAPTER EIGHT / COOLING AND EXHAUST SYSTEMS Thermostat / Hose replacement / Recirculation pump replacement / Seawater pump / Oil and power steering fluid cooler replacement / Exhaust elbow / Exhaust bellow and flapper valve / Exhaust tube and flapper valve / Exhaust manifold / Specifications. CHAPTER NINE / ELECTRICAL SYSTEM Battery / Alternator / Starter motor and solenoid / Starter relay / Fuel pump relay / EFI system relay / Ignition system / Oil pressure sender / Oil pressure switch / Engine temperature sender / Engine temperature sensor / Engine overheat switch / Exhaust overheat switch / Intake air temperature sensor (IAT) / Throttle position sensor (TPS) / Idle air control motor (IAC) / Knock sensor / Knock sensor module / Engine control unit (ECU) / Warning horn re

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