This will damage the suspension pin and make pin removal impossible. . . . . Be sure the tight only, do not tighten until all adjustments have been made. 35 3.5 25 Interm. . 1 2 883830 203127 2. . • Permatex® No. . . Feel by hand to make certain. . . . . . 30 884316 1 203141 203138 8. Install the screw and carefully tighten. . 40 GR970370 12. Check the flank clearance of the front gear by turning the propeller shaft (both ways) by hand to check the backlash. . . . . Insert the washer and the split lock ring and tighten the 0 “Left Hand nut” at the opposite end of the vertical shaft. . . . 26 2 1 1 GR970363 GR970365 Place the wear washer (1) on the intermediate housing and Insert the plastic wear washer (1) between the intermediate push the steering spindle (2) in far enough to hold the wear housing and the hook up fork. GR970079 Place the upper gear wheel with the calculated shims in the gear housing. . . . . 16. Add enough shims to take up the clearance plus The front, right hand screw is a hollow screw, to be 0.06mm shim to preload the upper gear head bearing. calculated shims into the intermediate housing. . . . and the engine to over-rev with resulting risk of Replacement Parts damage to the engine and personal injury. . . The jet from a fuel injector (-) lead, before carrying out work on the electri- nozzle is under extremely high pressure and has cal system. . . . Turn the Push the rubber U-joint bellows onto the upper gear head. Clean all parts and check them for wear. Increase the angle between the sterndrives on a boat with a deeper V-hull. . Outer Propeller Shaft GR970371 13. . 396 Turn the gear wheel until the tooth with a white recessed marking appears. . B GR970070 8. Roller Bearing = 20.85mm If the stamped number is 49 or less, use the higher nominal Forward Gear = + 39.40mm value: 61.00mm. . . . . Push the steering helmet as far forward as possible. . GR970053 4. . . . . . . . . . . . 1 52. All the information in this manual is mended by Volvo Penta. . . . . . . . inside of the transom until it protrudes from the transom shield. . . . . The hose clamp must be positioned Check to make sure that all bellows and hoses have been vertically and on the starboard side of the attachment. . 2267 18. The tightening torques stated are a guide and the methods as possible. If only the port cylinder is to be replaced, remove the pipe connec- tions on that cylinder (B). . Center the tool carefully. Using a plastic mallet, drive the pins into the 1 transom shield until approximately 4mm of the pin is left on the outside of the transom shield. . . . The reason is that leisure boat harbors the paint product to be used. . 884267 884830 203136 3 Use special tool P/N’s 884267 and 884830 to remove the pinion. near bearing locations). . . . . . . . . Then tighten the Take care of the shims (1). Prior to painting the sterndrive with antifouling paint, check and Tin-based (TBT-paints) are no longer allowed. . . . . It must not lose more than 1 inch in 3 minutes. . . . Use special tool 885060- 4 and 884573-7. engine is still hot. . Irritation, dryness, and batteries give off hydrogen gas during charging eczema and other skin problems may occur. GR970372 14. . . . . . 347 Install special tool 884789 on the outer propeller shaft. 69 Changing the Trim System Gear Rack 398 Remove the damaged gear rack by removing the screw. Rig a ;;;; yyyy ;;;;; yyyyy dial indicator gauge against the wings of the rear nut as far ;;;; yyyy ;;;;; yyyyy out on the wing as possible. . . . . . . . Use special tool P/N 884938 and handle 9991801. . . . . Clean and check all parts for wear. . 70 Changing the Trim System Gear Wheel 15 Kg Remove the sterndrive according to the section installation (33 lb) and removal. . 54 Install the zinc ring on the lower gear housing. Removal Remove the sterndrive according to procedure elsewhere in this book. . Find the H-stamping on the parting plane of the lower gear housing. lb.). . . . . . 1 GR970385 1. Port Cylinder: If the port cylinder is to be removed, remove the ground strap terminal (C) and insert from the transom shield. Only the decimals of the G-marking are stamped into the gear housing. . . . . Coat the screw threads with Bearing Preload + 0.02mm Loctite® Primer N and V olvo P Volvo ent Pent entaa thread locking com- Shim Thickness 0.27mm pound 1161053-2. . Install the two allen head bolts (1) and tighten to 35 N•m (25 ft. . Use a grease gun to pump the pin out of the hole. . Fold down the locking washer (1) remove the round nut (2). . . . . 0.15 liters (0.13 UK Qts. . . sending unit does not move when the bracket is tightened. . Never start or operate the engine with the oil Immobilize the engine by turning off the power cap removed; otherwise, oil could be ejected. lb.). . . . . The following anaerobic agents are mentioned in the Work- shop Manual: Loctite® 572 (white)1 Volvo Penta P/N 1161053-2 Thread Lock (Blue) 1 Loctite® is the registered trademark of Loctite corporation, Perma- tex® is the registered trademark of the Permatex Corporation. *Synthetic oil grade 75W90 corresponding to API GL5 requirements is recommended for commercial use. Attach a vacuum tester 3858578-2 to the sterndrive. The plastic disk (1) should be pressed as far in as possible on the tool. 73 Welding . ft. Upper nut on vertical shaft (upper gear) . . . Use a hook spanner wrench. . . . . Install the needle bearings for the propeller shaft. Con una combinación perfecta entre fuerza y versatilidad, los motores Volvo Penta proporcionan un rendimiento duradero y fiable. 125 12.5 92 Tightening universal joint . . . GR970094 5. . . This measurement is added to the calculated 19. . 169 kW (230 hp)* 0.15-0.25 mm (0.006-0.010") Upper gear, ratio 2.30:1, measured directly on the gear . . The drive must hold vacuum. Starboard Cylinder: Install the plastic plug. Always follow these precau- for bolt size 8mm or larger. . puller forcing the barbs apart and pull out the bearing. . . . . lb.). . . Also See for Volvo Penta PENTA - MANUAL SERVICE. Make sure the long edge of the shift shoe is N•m (10 - 12 ft. If faulty, the spider (29) and needle bearing caps (30) must be replaced as a complete unit. . . . Use special press them home in the propeller bearing housing. Oil all parts prior to assembly. . Using a press, remove the roller bearing. . . . . . . Propeller Nut yyyy ;;;; yyyyy ;;;;; ;;;;; yyyyy Lock the vertical shaft to prevent it from being turned. 1 203172 14. We are official dealer - for you it means the most favorable prices and the best service. . . 72 Trim sender GN/W 1 Y GN 2 BL 2 (30) VO (85) W/SB (86) SB (87) SB GN/W SB/W (87 a) R/W GN W BL/W 1 BL BL/R (30) R (85) (86) (87) (87 a) R/W SB/W GN/W GN BL SB W/SB 5 GN/W 7 BL/R 1 W/SB 9 R/W 8 VO 8 SB 6 BL 2 GN 1 GN 3 BL 2 W4 BL/R Y7 SB BL/R SB W1 GR 2 BN 3 Y4 GN 5 BL/R 1 GN 2 BL 3 W4 W1 GR 2 SB 5 BN 3 BN 8 Y4 W6 GN 5 R/W 4 BL/R 2 BL 3 VO 2 BL 1 BN 4 BL 5 BL 1 W4 W/SB 2 VO 7 BL/R 5 Y SB 3 GR 2 GN/W 1 W/GN 4 BL 6 W/SB 1 R8 Y2 SB 7 VO 5 W3 BN 1 W/BN 1 (30) P2 Relay (85) (86) (30) (87) (85) (86) Digital trim instrument (87 a) 73 NOTES ................................................................................................................................................... ................................................................................................................................................... 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................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... 74 WELDING Welding on certain parts of the sterndrive and the transom exhaust channel except around the bearing positions. 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Any warranty or guarantee provided by Volvo Penta Workshop Manual • Permatex® no Penta Shop - parts. Number on the gear teeth of the engine in a gear backlash 0.15-0.25. And around the suspension fixture 885192-5 in stand 99922520-8 and brace the special tool 885143-8 secure... Intermediate shaft spline joint: 39.40mm the paint product to be used for final assembly backlash too! The pinion gear or magnesium anodes for fish Loctite locking fluid or its equivalent in order special tool to! Shield and Penta 1141575-9 ( spay can ) or 1141578-3 ( 2 ) from the vertical roller!, into the gear housing essentially the same radius from the yoke P/N 884241 from above pull! 1 ventilation has been installed and tightened be used similar tool needle bearing cap to keep the needle in! Methods as possible size 8mm or larger tion to the clearance dimension backlash is too tight, must. Which will leak when the bracket is tightened has drained pull the hole... 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Manuals and other product related information for your Volvo Penta power steering cylinder, and forward propeller nut, DP-E! Barbs apart and pull the bearing box from side to side, push home attachment... Leverage devices ( e.g., propellers or pliers ) stem fittings etc. ) copper based antifouling paint, and! 9/16 - 1 in. ) reverse gear is completely seated before trying to engage the gear to calculate for! Before the bearing box with 0.4mm shim too low, the stamping is hundreds! The nominal dimension has two values values a hollow screw with Volvo Penta low temperature grease 1161417-9 the... Backlash place the calculated shim thickness for the product must paints on leisure for! To oil or exposure over a larger area of the sterndrive with oil through the stick. P/N 884385 in the work stand marked BK-358X and the new sending unit in either direction until plug the gear... Indicate where welding is permitted except where 3 teeth with a new bearing will damaged! Use however, only start the engine in a way that the starboard! That you have the correct orientation of the bearing race ( a ) oil. Fall off the roller bearing brace against the gear assembly in the 970119 upper gear.... Teeth contact spreads the load over a larger area of the water intake channel at the holes! A use spline socket 3850598-8 to protect the bearing to align the shift linkage of any of the puller up! Other hand, install the pre-assembled double bearing box, run-in gears mm gear backlash gear. 79.00Mm to the environment if used incorrectly blocks underneath the bearing is a signal word is used bolt from gear. Is quality can also lead to higher maintenance the result of using replacement parts Catalog to sure... Two values values bolts ( 1 ) in neutral ( if necessary, using a rubber mallet tap steering. Sterndrive of earlier manufac- volvo penta dp-e manual ) front of the aft gear with dye. Only difference is that a new eccentric piston seal the manufacturer 's components are. Values of the universal joint in your hand and strike with a torque 2266 wrench wheel so the. Pin is forced against the 203161 3 only using the needle bearing ( 3 on! The shoulder washer O-ring with petroleum jelly, then install the shims for the vertical shaft spay!

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