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Lay up and Launching for Volvo Penta Diesel and Petrol engines

Investing a couple of hours each year in checking and completing basic maintenance on your engine/s and drives/s will be time well invested. Your engine will run more reliably, economically and use less fuel, with less chance of unnecessary breakdowns. Life at sea will be safer.

We have detailed below some important checks which should be carried out before lay up, during and before re-launch. If you are unsure of any of the information please contact a member of our team or drop us an email and we will be more than happy to offer any advice we can. If you do not wish to do it yourself, certain complicated jobs are, of course, best left to an authorised dealer since they call for both specialised knowledge and special tools. We recommend you always use genuine Volvo Penta parts, that way you can be confident that the parts you use will be of the right quality and fit perfectly.

Remember the environment – collect any oil, coolant, degreaser, paint etc. and dispose of them safely and appropriately.

Oil & filter changes

You should change the engine oil and oil filter after approximately 100 running hours, or at least once per season. Choose Volvo Penta engine oil which has good inhibiting qualities and you will not need to add any special inhibiting oil for a normal winter lay-up. A new oil filter will remove any soot and metal particles from the oil and prevent unnecessary engine wear. Genuine Volvo Penta filters are tested and specially designed to suit each particular engine type.

• Change the engine oil in the laying up season, run the engine for a while, check for oil leaks, re-check oil level
• Change the transmission oil
• Always check oil and all other fluid levels before starting the engine/s for re-launch.

Cooling system – Sea water cooled engines

Regular maintenance and servicing of the cooling system is an effective way of preventing damage from overheating. It is also important to inhibit the cooling system for the lay up season in order to avoid frost damage and corrosion. The engine and reverse gear cooling water ducts must be flushed and drained off.

• Never let the water pump run dry
• Work on the cooling system is best carried out on land. Otherwise there is a risk of water getting into the boat
• Let the engine run for a while in order to flush away any sludge and salt that could otherwise cause rusting
• Run a mixture if anti-freeze/inhibitor into the engine. Leave the liquid in the system, as it provides good protection against freezing and corrosion
• After inhibiting, remove the sea water pump impeller, rinse it well and keep it in a tightly sealed plastic bag in a cool place during the lay-up period
• Check and clean the sea water filter, if fitted.
• We recommend that you install a new impeller before re-launch

If you need to protect your engine/s for longer than the normal lay up period we recommend you empty the cooling system completely and inhibit the engine with an inhibitor, to protect the cooling water ducts.

• On re-launch check all plugs and drain cocks are closed
• Some engines have zinc anodes on the plugs which act as sacrificial anodes in the cooling system. An anode must be replaced when about 50% of its volume has been used up

Cooling system – Fresh water cooled engines

Regular maintenance and servicing of the cooling system is an effective way of preventing damage from overheating. It is also important to inhibit the cooling system for the lay up season in order to avoid frost damage and corrosion. The engine and reverse gear cooling water ducts must be flushed and drained off.

The fresh water cooled engine has two cooling systems, the engine block and cylinder head. The oil cooler, heat exchanger and on some engines, exhaust pipes are sea water cooled and should be inhibited as with sea water cooled engines (see: sea water cooled engines above).

• Never let the water pump run dry
• Work on the cooling system is best carried out on land. Otherwise there is a risk of water getting into the boat
• Avoid mixing different types of coolants as it drastically diminishes its corrosion protective qualities
• Do not mix coolant with other additives

Check the freezing point of the coolant with a hydrometer and top up the cooling system if necessary. The coolant mixture loses its corrosion protective qualities with time and should therefore be changed every other year.

• Check and clean the sea water filter, if fitted
• Inhibit the sea water cooled side of the engine (see: sea water cooled engines above)
• Before re-launch check the level of the fresh water system and make sure that all plugs and drain cocks are fully closed
• Install new sea water pump impeller as required

Thermostat

If your instrument panel has a temperature gauge you will be able to see whether the engine stays at the right working temperature or not. Excessive temperatures are often caused by blockages in the coolant intake, coolant ducts, heat exchanger, or by a defective impeller. Too low a temperature is usually caused by a faulty thermostat.

• Check and replace the thermostat as required

Impeller

The impeller pumps cooling water through the engine cooling system. It is therefore, an extremely vital safety feature. A worn or damaged impeller should be replaced immediately. We recommend that you keep a spare impeller and gasket/seal onboard.

• After inhibiting, remove the impeller, rinse it well and store appropriately during the lay up period
• Install a perfect impeller, cover and gasket/seal before re-launch

Cooling water hoses/exhaust hoses

As rubber becomes brittle with time, you should occasionally check the hoses on your engine/s and drive/s for any signs of cracks or damage

• Leaking cooling water hoses are a safety hazard and can cause the engine to overheat or leak water into the boat. Check and replace as required during the lay-up period
• Leaking exhaust hoses can cause dangerous exhaust fumes onboard and allow water to get into the boat
• Check hoses and tighten clamps, replace as required during the lay up period

Drive belts

Check the condition of all belts, a perfect belt gives a better generator charging effect while, at the same time, reducing the risk of overheating.

• Always keep spare belts onboard
• Replace belts as required, before re-launch tighten the belts and adjust the tension
• Remember to re-check the belt tension after a few hours running, re-adjust, if necessary

Fuel system

Use genuine Volvo Penta parts when servicing the fuel system. It is particularly important to avoid getting any dirt into the system

• Fill the fuel tank for the lay up period to prevent condensation build up in the tank
• If you have an extra fuel filter with water separator, any water should be drained from the container
• Before re-launch, vent the fuel system (see operator’s manual). Run the engine warm and check for leaks

Air filter/ Air intake silencer

Replace air filter insert or clean air intake silencer at least once per season, an engine with a clean air filter can work more efficiently and uses up less fuel
Replace the crankcase ventilation filter (if any)
Use genuine Volvo Penta filters, they are specially designed and tested for each particular engine type.

Electrical system

Sea air, which can be humid and salty, is a tough environment for the electrical system to operate in. The engines electrical system can be affected by leaking current, oxidation and voltage drop if you do not overhaul it regularly.

• Check the wiring for damage, serious corrosion damage can occur within a short time if leakage currents knock out the galvanic corrosion protection
• Remove battery cables, clean the cable clamps and apply appropriate grease to the battery poles
• Check the battery electrolyte level and top up as required
• Charge the batteries (note: a battery will discharge when not in use)
• Clean and dry dirty and damp cables, spray the connection points, contacts and fuse holders on the engine and under the instrument panel with appropriate lubricant
• Before re-launch check all fuses and make sure you have spares onboard
• Install fully a charged battery before re-launch

Oil changes – Drive/Reverse Gear

To avoid possible injury it is absolutely vital that you follow the safety recommendations in your operator’s manual very carefully when you work with the drive and transom shield

Change the oil in the drive/reverse gear at least once per season. Be careful to use the correct quality oil.
If the old oil looks grey, it could be from water leaking into the drive. You should contact your local Volvo Penta Dealer for immediate advice, info@motortechmarine.co.uk

• Fill the drive with new oil to the right level and run the engine for a moment to allow the oil to circulate
• Before re-launch, re-check the oil level
• If you have a Sail-drive, the rubber seal and clamp between the drive and engine should be checked every year. If damaged, it must be replaced with a new seal immediately. Otherwise it should be replaced every seventh year. Also check the seal on the hull of the boat for signs of wear or damage

Drive

The drive bellows are subjected to tremendous wear from movement and from salt and impurities in the air and water. If water gets in via the drive joint bellow it can cause extensive direct damage and, in many cases, costly subsequent damage. So replace the bellows regularly (at least every other year).

• Carefully check the exhaust and drive joint bellows and replace as required. Check the hose clamps on the bellows are firmly tightened and lubricate the grease nipples on the drive and steering fork (use grease gun)
• For reverse gear engines: Check the propeller shaft seal. Vent the bushing and apply water repellent grease into the seal. Upon re-launch the seal will need to be vented
• Before re-launch check all anodes and replace as required. The anodes must be replaced if they are more than half used up. Use genuine Volvo Penta anodes, as the wrong mix of material in the anode can lead to serious corrosion damage to the drive and propeller
• NEVER PAINT OVER THE ANODES

If the boat is used in fresh water (or brackish water containing little salt) the drive anode should be replaced with a magnesium anode 

Propeller

A propeller must be in good condition to give you maximum output from your engine. A damaged propeller causes vibrations and reduced speed. In bad cases it can even cause bearing damage. Even minor damage to the propeller can easily lead to cavitation (looks like corrosion damage), repair such damage and always keep a spare propeller onboard.

The mechanism of the folding propeller must be greased with Volvo Penta water resistant grease. Refer to your instruction manual when removing and refitting propeller/s.

• At lay up remove the propeller/s and grease shaft/s with appropriate grease
• Before re-launch refit the propeller/s, remember to grease the shaft/s first

Ignition system

Maintaining the ignition system is important in order for the engine to run well and consume less fuel. If you do not have the right equipment and knowledge for the job, then all the adjustments to the engine ignition system should be carried out by a Volvo Penta Dealer. Faulty adjustment of the ignition system can result in engine damage and reduced fuel economy.

Use genuine Volvo Penta components for the ignition system, they meet all marine safety requirements. Make it a rule to change spark plugs at least once every year, this will help to prevent any starting problems, back-firing etc. more information can be found in your operator’s manual.

• At lay up clean and dry the ignition cables and distributor cover, loosen the distributor cover and dry inside. Spray inside and outside using a moisture-repellant spray
• Replace any damaged or worn parts
• Before re-launch, install new spark plugs. If the engine is equipped with breaker points these should be replaced too, if necessary. Replace condenser, distributor cap and rotor if required
• Clean and dry the ignition cables and distributor cover
• Get a Volvo Penta workshop to overhaul the ignition point setting, if you do not have access to the special tools

Ventilation

Be careful to ensure good ventilation during the lay up period. The air must be allowed to circulate throughout the boat. Keep the doors and hatches, including the engine compartment open in order to avoid condensation and mould.

Clean the engine compartment. A clean engine compartment is a prerequisite for maximum safety onboard, and makes servicing work that much more agreeable.

Further information

There is an operator’s manual providing you with more detailed information on each particular engine. Time intervals mentioned in the page are only general and can vary between different engine types. Entirely different intervals apply, if you use the engine/s for commercial purposes or in very polluted waters

We hope you find this guide informative, however if you have any queries or questions please do not hesitate to contact us; Telephone +44 (0)23 92201171 or email info@motortechmarine.co.uk

The information on this page has been extracted from the Volvo Penta Lay-up and Launching guide (copy available on request)

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Last Updated: September 06, 2008