Volvo PENTA Wartungshandbuch

7Repair InstructionsThe work methods described in the Workshop Manualare applicable for a workshop environment. The drivehas removed from the boat and

97Repair instructions9. Install special tool 884830 onto the splines end andturn the gear in the set direction of rotation, clockwisefor left handed p

98Repair instructionsFinal assembly1. Dismantle pinion and gear and clean parts frommarking dye and then assemble with the calculatedshims. Then insta

99Repair instructionsReconditioning the lower gear,models 280-DP, 290-DP and DPDisassembly1. Clean the sterndrive externally.2. Drain the oil by remov

100Repair instructions7. Remove the two Allen-head screws from the propel-ler bearing housing. Key width: 3/8”.8. Install special tool 884789 on the o

101Repair instructions13. Remove the nut from the pinion gear.Use a 23 mm wrench.NOTE! Do not discard the nut. Put it aside for use inthe shimming pro

102Repair instructions17. Remove the forward gear bearing outer race fromthe lower unit, using special tool 884794 and slidehammer 884161. Remove the

103Repair instructions21. Install a knife puller on the outer propeller shaftroller bearing. Using a press, remove the roller bear-ing.IMPORTANT! Make

104Repair instructions25. Remove the outer bearing race using special tools884796 and handle 9991801.IMPORTANT! Center the tool carefully. Locate apai

105Repair instructions30. Check the bearing race. Replace as necessary,using a knife puller. Clean and check all parts forwear.AssemblyShimming the fr

106Repair instructions3. The nominal measurement of the forward gear is39.50 mm. The tolerance (±) is engraved on the gear.All engraved numbers are de

8General InformationSafety instructions forfluororubberFluororubber is a common material used in sealingrings for shafts and O-rings.Hydrofluoric acid

107Repair instructions6. Use special tool 884263 to press the gear and bear-ing assembly onto the propeller shaft. Use special tool884799 to protect t

108Repair instructions12. Find the “H”-marking on the parting plane of thelower gear housing. The “H”-stamping in this instanceis 37. Remember, the st

109Repair instructions14. The nominal measurement of the vertical shaft is217.75 mm. This measurement is added to the cal-culated pinion measurement o

110Repair instructions18. Hold the pinion nut with a 23 mm socket. Use spe-cial tool 884830, or 3850598 as an alternative, and atorque wrench. Torque

111Repair instructions21. The nominal measurement of the aft gear is39.50 mm. Find the variation marking on the gear. Inthis case it is +10. Remember,

112Repair instructions27. Now add the front and rear gear shims.Add:Forward gear shims 0.60 mmAft gear shims + 0.31 mm0.91 mmAdd nominal value + 120.0

113Repair instructions29. Press the needle bearing into the propeller shaftwith the text on the bearing turned facing the tool. Usespecial tool 884806

114Repair instructions35. Grease the bearing box and install on the lowerunit. Tighten the allen bolts to 40 Nm (29 lb.ft.).36. Place the outer bearin

115Repair instructionsChecking preload39. After calculating the shims required according topoints “A” and “B”, place the calculated shim on topof the

116Repair instructions43. Move the dial indicator gauge to the outer nut.Measure the backlash of the rear gear the same wayas the front gear. The clea

9General InformationSealantA number of different types of sealant and locking flu-ids are used on the engine. The sealant has differentproperties for

117Repair instructions47. If the contact pattern is toward the root of thetooth and at the big end, the shims should be in-creased under the front and

118Repair instructions3. Grease the new seal rings and install in the propel-ler shaft. Turn the steel edge (1) facing forward. Usespecial tool 884975

119Repair instructions9. Install new O-rings (1) on the bearing box. Coat theentire sealing surface and O-rings with Volvo Pentapart no. 1141570-0 sea

120Repair instructions1. Place the bearing race on the bearing and hold inposition. Using a depth gauge, measure the bearingheight above the lower uni

121Repair instructions5. Use new screws and washers. Coat the screwthreads with thread locking compound, Volvo Pentapart no. 1161053-2, or Loctite® 24

122Repair instructionsShimming the upper gear to theintermediate housing1. Measure the distance from the bottom of the uppergear housing to the top of

123Repair instructions6. Install the upper gear housing on the intermediatehousing. Use new Allen bolts (1, 2 pcs), washers (2,2 pcs) and nyloc nuts (

124Repair instructionsBefore filling the drive with gear oil, it must be pres-sure and vacuum tested to verify proper sealing duringassembly.Pressure/

125Repair instructionsInstalling the sterndriveModels 280 and 285There are 2 types of exhaust bellows. One type withan exhaust valve and one without.

126Repair instructions6a. Sterndrives of later manufacture:Lower the steering helmet and grease the ‘attachmentbolt’ with grease. Turn the recessed ho

10Special toolsIn all cases where it has been practically possible tools have been punched with their tool number, excludingthe last digit. The last d

127Repair instructions7. Check that the control lever and the shift lever ofthe sterndrive both are in a neutral position. Removethe locking nut for t

128Repair instructionsInstalling a ‘short hub’ type ofpropeller (B)1. Grease the propeller shaft with a thin layer ofgrease.2. Install the fishing lin

129Repair instructionsThe Duoprop, earlier modelCheck the speed range of the relevant boat and selectthe correct propeller. See Propeller recommenda-t

130Repair instructionsThe electro-mechanicalsterndrive tilting device,model 280/285Repair instructionsOperating failures of the sterndrive tilting dev

131Repair instructions1c. Mechanical faultCheck to make sure that the cover does not pressagainst the limit switch by removing the cover andtesting th

132Repair instructionsModels 290, SP and DP1. Install the exhaust bellows on the transom shield.Turn the hose clamp so that the tightening screwends u

133Repair instructions5. Remove the cover over the shift mechanism.Hang a hose clamp on the sterndrive and install theyoke on the sterndrive. Then lif

134Repair instructions9. Push the sterndrive forwards. Lift up the trim cyl-inders simultaneously and continue to push thesterndrive forwards.10. Push

135Repair instructions13. Pull down the retaining pawl and lift up the stern-drive sufficiently to allow the installation of specialtool 885143 betwee

136Repair instructions17. Install the cotter pins (1). Fold the ‘legs’ back-wards carefully.18. Lower the steering helmet and align the helmetbushing

11Special tools884267-6 Tool, dismantling vertical shaft884283-3 Drift for the installation of sealing rings inpropeller bearing housing and of propel

137Repair instructionsAdjusting the retaining pawl,model 290a) Set the control lever in the ‘Forward’ position andcheck that the lever (8) does not to

138Repair instructionsLocking the propeller cone on sterndrives of earliermanufacture is done by a folding washer and on stern-drives of later manufac

139Repair instructionsChanging the direction of thepropeller rotation, SP drivesThe sterndrives are supplied adjusted for left hand ro-tation ‘A’. In

140Repair instructionsAdjustment of trim finThe trim fin is factory set at 5° towards port side. Af-ter installation the adjustment of the trim fin sh

141Repair instructionsDuoprop propellers are available in two versions asfollows:A-marked propellers shall only be used with dieselengines.B-marked pr

142Changing trim cylinders,models 290, SP and DP1. Remove the sterndrive when the boat is on land.Also remove the exhaust bellows and the universaljoi

143Transom shield7. Remove the locking bolt for the trim cylinder dowelpin. Key width 10 mm.Trim cylinders, all modelsPart no.9401946. Install a greas

144Transom shield11. Always use a new O-ring (1) on the dowel pin dur-ing reassembly. Check the pin hole and pin forscratches or other damage. Positio

145Transom shield13. Remove any shipping plugs installed in the newtrim cylinder.Install the pipes and the hoses on the new trimcylinder.WARNING! Make

146Transom shield18. Should the low pressure hoses (1) and high pres-sure hoses (2) need to be disconnected for any rea-son it is vital that they be r

12Special tools884794-9 Puller, forward bearing race remover, low-er884795-6 Bearing install tool, lower884796-4 Drift, bearing remover, lower884797-2

147Transom shieldChanging steering helmetTo ensure the integrity of the steering system thesteering helmet is not serviceable as a separate partfrom t

148Transom shield23. Install a new bushing (8) into the new steeringfork.24. Align the square/the splines on the steering forkwith the square in the t

149Transom shield28. Install a new seal (9) and O-ring (7) on the gearwheel.Install the trim sending unit, gear wheel and gear rack.See chapter Trim S

150Trim systemChanging the sending unit1. Lower the sterndrive to the full down position. Turnthe helm full starboard. Using a 13 mm wrench, re-move t

151Trim system5. -4 should be shown in the instrument window for a12º transom angle. Move the sending unit in eitherdirection until the correct number

152Trim system3. Turn the gear wheel until the tooth with a white re-cessed marking appears.4. Install the new gear rack with the marked tooth ofthe g

153Trim system8. -4 should be shown in the instrument window for a12º transom angle. Move the sending unit in eitherdirection until the correct number

154Trim system4. Grease the new gear wheel shaft and O-ring liberal-ly with Volvo Penta Propeller shaft grease 828250-1.Install the new gear wheel wit

155Trim system8. After all adjustments are made, tighten the trimsender bracket hold down screw. Be sure the sendingunit does not move when the bracke

156Trim systemRemoving the trim pump from theboatTurn off the main battery switch. Disconnect thetrim pump wiring harness, ground cable from the fly-w

13Special tools884978 884982 885008885009 885043 885127 885143 885146885148 885153885197 885207 885208884975-41)Installation tool884976-21 )Protection

157Trim systemReplacing adapter and pumpassemblyTo install a new filter, place a 5/8" socket over the fil-ter and gently tap it down using a hamm

158Trim systemThe relief valve assembliesIf the original factory fitted valves have to be re-moved, this will alter the factory setting, and newvalves

159Trim system4. The instrument, when trimmed down and with aknown transom angle, shows the following figures,see table below:5. If the instrument sho

160Sterndrive extensionsInstallation instructions for 1"and 4" extensions:Drain the oil from the sterndrive.Remove the cover over the shift

161Sterndrive extensionsThe 1" extensionCoat the contact surfaces with a sealant. Use the 3new O-rings and the oil pipe from the extension kit. I

162WeldingWelding on certain parts of the sterndrive and thetransom shield is allowed. Extreme caution must beused to prevent damage to the precision

163PaintingPainting the sterndrive andunderwater hullGeneralMost countries have introduced legislation controllingthe use of anti-fouling agents. In s

164Electrical wiring diagramsModel 280, tilting deviceReferences:1. Relay box2. Relay3. Limit switch4. Push rod, retaining pawl5. Connector6. Electric

165Electrical wiring diagramsModel 280, Power trim1. Pump motor2. Relay3. Fuse4. Switch5. Body6. Trim gauge7. Sender8. Relay9. Bypass switch10. Trim l

166Electrical wiring diagramsModel 290, Power trimEarlier modelCable colour codesR= redSB = blackGN = greenBL = blueW = whiteR/W = red/whiteGN/W = gre

14Special tools385587699918013810105-1 Pin installer, intermediate3810152-3 Drive pressure tester3850598-8 Spline socket, upper & lower3850608-5 S

167Electrical wiring diagramsModels 290, SP and DP, Power trimLater model1. Oil pump2. Fuse 55 amps3. Trim sender4. Trim indicator5. Switch6. Switch-r

168Technical dataModels 280, 280T, 280PT, 285, 285A and 290General DataType designation...

169Technical DataLubricating systemPump, type ... Circulation pump for distr

170Technical dataModels 280-DP, 280DP/PT, 290DP and 290A-DPGeneral DataType designation...

171Technical DataLubricating systemPump, type ... Circulation pump for distr

172Technical dataModels SP-A, SP-A1, SP-A2 and SP-CGeneralDataType designation... Aq

173Technical DataTightening torques Nm Lb. ft.Upper nut on vertical shaft (upper gear)... 125 92Tightening universal j

174Technical dataModels DP-A, DP-A1, DP-A2, DP-B, DP-B1, DP-C and DP-C1General DataType designation...

175Technical DataTightening torques Nm Lb. ft.Upper nut on vertical shaft (upper gear)... 125 92Tightening universal j

176References to Service BulletinsGroup No. Date Concerning...

15AQ 280 PTPower trimRatio:1.61:11.89:1Oil:Same as engineQty: 2.6 liters (2.74 qts)AQ285AQ 285AElectro mechanical tiltPower steeringOil:Same as engine

Report formDo you have any complaints or other comments about this manual. Pleasemake a copy of this page, write your comments down and send them to u

7731624-8 English 06–2003

16Drive models and generationsAQ 290AQ 290AOil:Same as engineQty: 2.6 liters (2.74 qts)Ratio:1.61:11.89:12.15:1New transom shieldHook up forkSP-ARatio

DrivesWorkshop Manual2(0)B C280, 280-DP, 285, 290, 290-DPSP-A, SP-C, DP-A, DP-B, DP-C

17Drive models and generationsSP-A2Ratio:1.61:11.89:1Sliding sleeve (steel)CoverGear setOil:Same as engineorFully syntheticAPI GL-5 SAE 75W–90Qty: 2.

18Drive models and generationsDP-B1Oil:Fully syntheticAPI GL-5 SAE 75W–90Qty: 2.7 liters (2.85 qts)Ratio:1.78:11.95:12.30:1CoverBall bearingUniversal

19Section through the sterndrive1. Steering arm2. Electro-mechanical tiltingdevice3. Steering yoke4. Rubber cushion5. Universal joint6. Steering helme

20Design and functionSection through the sterndrive, showing model DP1. Transom shield2. Trim cylinder3. Hook up fork4. Steering yoke5. Steering helme

21Removing the sterndriveModels 280, 285 and 2901. Remove the propeller of the Singleprop sterndriveaccording to the picture.2. Remove the propellers

22Removing the sterndrive3. Remove the Allen-head bolts holding the zinc ringand remove it.4. Remove the oil drain plug and drain off the oil. Alsorem

23Removing the sterndrive7a. Sterndrive models 280 and 285: Remove thesteering helmet and the universal joint rubber bellowsfrom the upper gear housin

24Removing the sterndrive7b. Sterndrive model 290: Remove the steering hel-met and the universal joint rubber bellows from the up-per gear housing (1)

25Removing the sterndrive6. Remove the shift linkage cover.1. Disconnect power to prevent accidental starting.2. Move control to reverse.3. Loosen pro

26Removing the sterndrive7. Remove the cotter pin and washer from the shiftcable end. Remove the end pivot pin from the cable.8. Loosen screw holding

27Removing the sterndrive11. Remove the cotter pin on the trim cylinder pin. Re-move the trim cylinder pin. Raise the drive manuallyand insert special

28Removing the sterndrive15. Install special tool 885146 and remove the stern-drive from the transom shield.885146

29Repair instructionsUpper gear housing1. Place a drain pan under the sterndrive. Remove thedrain plug (1) and drain oil from drive. Reinstall thedrai

30Repair instructionsDisassembly, models280, 285 and 2901. Remove the shift rod (1) from the shift plate (2). Re-move the screws (3) and the nuts (4)

31Repair instructions8. Remove the left hand threaded nut (1) on the ver-tical shaft. Use special tool 884830 as a counter-holdon the splines shaft wh

32Repair instructions9. Lift out the upper gear and the bearing box as wellas the engagement sleeve.10. Lift off the upper gear housing from the speci

33Repair instructions16. Remove the locking ring (1) and the sealing (2).NOTE! Always replace the sealing!17. Press out the input gear. Use special to

34Repair instructions18. If required press off the roller bearing (1) from thegear using a knife puller. The bearings (1) and (4)can be changed separa

35Repair instructions3. Rotate the bearings a couple of turns to allow themto ”set”. Check the prestressing with a spring scaleand a piece of string,

36Repair instructions5. Measure the depth of the recess in the collar wash-er “E” and add to this measurement a number ofshims (5) that the measuremen

1General Information ...3Safety Information ...

37Repair instructionsShimming the forward and reversegearsMethod 19. Measurement “A” is fixed at 62.05 mm (2.443").10. Add or subtract the plus o

38Repair instructions12. Insert a 0.2 mm (0.008") shim (1) under both for-ward and reverse gears as a starting point. The shimvalue is a number d

39Repair instructions15. Brace the special tool 884387 in a vice and installthe gear housing in the tool.16. Install the preassembled double bearing b

40Repair instructions19. When the correct backlash has been obtained,dismantle the double bearing box and the clamp ring.In order to obtain a clear pi

41Repair instructionsFinal assembly1. Install the lower gear along with the calculatednumber of shims.2. Install the washer (1), the locking ring (2),

42Repair instructions3. Install the needle bearings (1) and the spacer ring(2) between the bearings in the lower gear and insertthe shaft in the gear.

43Repair instructions7. Measure the shim thickness between the clampring and the gear housing as follows:Hold the double bearing box as indicated in t

44Repair instructions10. Install the shims and the 2 new O-rings on thedouble bearing box.11. Install the clamp ring and the double bearing boxon the

45Repair instructions14. Coat the contact surface with Volvo Penta part no.1141570-0 sealant and install the sealing ring (1) in away that the sealing

46Repair instructions1. Install the upper gear housing on special tool884830. This special tool, of earlier manufacture, alsocarries the part no 88426

2ContentsInstalling the sterndrive ... 125Models 280 and 285 ...

47Repair instructions5. Remove the 4 screws holding the gear housing cov-er.6. Remove the cover.NOTE! The front right hand screw (1) is a hollowscrew

48Repair instructions10. Remove the needle bearings (1) from the upperand lower gear cup assemblies.Model 290A only: Also remove the spacerring (2).NO

49Repair instructions14. Press out the input gear. Use special tools 884938and 884266. Remove the crush sleeve and discard.15. Turn over the double be

50Repair instructions1. Install the outer bearing race. Use special tool no884932.NOTE! Make sure that the double bearing box is posi-tioned horizonta

51Repair instructions2. Install the bigger roller bearing on the gear wheel bypressing it on. Use special tool 884263.NOTE! Protect the gear teeth. Th

52Repair instructions6. Insert the universal joint into the double bearing boxand brace the universal joint in a vice. Install the coni-cal washer and

53Repair instructionsForward and reverse gears8a. Drives without integrated bearings:Lubricate the bearings (1) and press the bearing intotheir respec

54Repair instructionsShimming the forward and reversegearsMethod 110. Measurement “A” is fixed at 62.05 mm (2.443").11. Add or subtract the plus

55Repair instructions13. Insert a 0.2 mm (0.008") shim (1) under both for-ward and reverse gears as a starting point. The shimvalue is a number d

56Repair instructions18. Use sufficient number of shims to create clear-ance of max. 0.1 mm (0.004”) between the top coverand the upper gear housing a

3Safety InformationIntroductionThe Workshop Manual contains technical data, de-scriptions, and repair instructions for the designatedVolvo Penta produ

57Repair instructions20. Remove the double bearing box when the correctbacklash has been obtained.To gain a clearer picture of the contact pattern, co

58Repair instructionsFinal assembly1. Install the lower gear along with the calculatednumber of shims.2. Install the washer (1), the locking ring (2),

59Repair instructions13. Install the needle bearings (1) and the spacer ring(2, model 290A only) between the bearings in thelower gear and insert the

60Repair instructions9. Coat the surfaces between the double bearing boxand the gear housing with sealing compound, VolvoPenta part no. 1161099-5 or P

61Repair instructions11. Coat the cover with sealant, Volvo Penta part no.1141570-0 and install the sealing ring (1) so that thesealing for the front

62Repair instructions11. Remove the locking rings (1) holding the needlebearing in the yoke.NOTE! To avoid having the locking rings “jump out”and gett

63Repair instructions5. Use a small amount of water resistant EP bearinggrease, Volvo Penta part no. 1161246-2, to retain theneedle bearings in the ca

64Repair instructionsShift mechanism type 12. Knock out the load pin (1, figure above) and pull outthe pin (2). Remove the locking wire (3), the sprin

65Repair instructions4. Insert the excentric piston (1). Install the pin (2) andlock it with the load pin (3). Make sure that the loadpin centers in t

66Repair instructionsShift mechanism type 28. Knock out the load pin (1, figure above) and pull outthe pin (2) and the excentric piston (3). Remove th

4General InformationStop the engine and close the bottom valve be-fore working on the cooling system.Only start the engine in a well-ventilated area.E

67Repair instructions9. Lubricate the sealing ring abundantly and install itwith the steel edge (small clearance) facing inwardsthe gear housing.10. I

68Repair instructionsShift mechanism type 315. Remove the sliding shoe (1) and the spring (2) andthe O-ring (3).12313. Set the shift mechanism in a po

69Repair instructions16. Knock in the load pin as far as necessary to freethe pin (1).117. Pull out the pin.18. Pull out the excentric piston.19. Tap

70Repair instructions24. Install the shift mechanism in the gear housing ina way that the screw (1) is displaced towards star-board.NOTE! Make sure th

71Repair instructions26. Remove all adjustment shims (1) and tighten thescrew. Now it is no longer possible to turn the verticalshaft in the upper gea

72Repair instructions31. Do not attempt to mount the special tool 3856761on any raised portion or raised lettering on the shifthousing. The tool shall

73Repair instructionsIntermediate housingReconditioning theintermediate housing, model280 and 2851. Remove the 2 screws holding the hose connection(1)

74Repair instructions5. Press out the bushing (1). Use special tool 884259.6. Should the shift yoke need to be replaced, removethe cotter pin (1). The

75Repair instructionsAssemblyOil all moving parts and the screws prior to as-sembly.9. Install the shaft (53) on one of the retaining pawls(42) and th

76Repair instructions12. Press in both sealing rings. Use special tool884259.NOTE! The sealing rings are to seal against waterand thus have to be inst

5General InformationUse the lifting hooks mounted on the engine/reverse gear when lifting the drive unit. Alwayscheck that the lifting equipment is in

77Repair instructions16. Install the shift yoke (3) and push in the shaft (2)and lock it with the cotter pin (1).NOTE! A washer must be installed on e

78Repair instructions3. Press out the sealing rings and the needle bearing.Use special tools 884259 and 9991801.NOTE! There is a sealing ring on each

79Repair instructionsAssemblyOil all moving parts and the screws prior to as-sembly.7. If necessary the retaining pawl is dismantled as fol-lows:Remov

80Repair instructions11. Press in both sealing rings. Use special tool884259.NOTE! The sealing rings are to seal against waterand thus have to be inst

81Repair instructions15. Insert the wear washer (1) between the steeringyoke and the intermediate housing and push in thesteering spindle until the co

82Repair instructionsReconditioning theintermediate housing, modelsSP and DP1. Remove the 2 screws holding the hose connection.Remove the hose connect

83Repair instructions5. Should the shift fork require replacement, removethe cotter pin (1). Remove the shaft (2) and removethe shift yoke (3). To ins

84Repair instructions9. Place the wear washer (1) on the intermediatehousing and push the steering spindle (2) in farenough to hold the wear washer.10

85Repair instructions13. Install the shift yoke (3). Align the shift yoke withthe shaft hole in the intermediate housing. Push theshaft (2) through an

86Repair instructionsLower gearReconditioning the lower gear,models 280, 285, 290 and SPDisassemblyThe propeller shaft1. Install the suspension fixtur

6General InformationAbout the Workshop ManualThis Workshop Manual contains technical information,descriptions, and repair instructions for the standar

87Repair instructions5. Remove the 6 nuts holding the washer (1) andknock the propeller shaft out of the bearing housing.Use a copper mallet or its eq

88Repair instructions9. Knock out the 2 sealing rings (1) off the propellerbearing housing.10. Fold down the tab on the locking washer (1) andremove t

89Repair instructions13. Lift out the pinion (1) and the needle bearing wash-er (2).NOTE! The needle bearing is a full needle type ofbearing with loos

90Repair instructions17. Should the needle bearing of the propeller shaft bedamaged, use special tool 884316 to remove it. In-sert the puller into the

91Repair instructions3. Grease abundantly the outer race (1) with greaseand insert the 27 needles, well cleaned, into the ringletting the grease hold

92Repair instructions6b. Models 280, 290 of later manufacture: Install thethick spacer ring and tighten the plastic insert locknut.Use a hook spanner

93Repair instructions10. Remove the conical roller bearing race in the inter-mediate housing (if the old bearing can still be used).Use special tools

94Repair instructions14. Press on the gear wheel on the propeller shaft.Use special tools 884265 and 884263.15. Install the locking washer (1) and pre

95Repair instructions2. The gear length is fixed at 5.85 mm (0.230"). Addor subtract the plus or minus marking of the gearwheel. Subtract from th

96Repair instructions5. Install the propeller shaft with its bearing box in thegear housing. Tighten the screws with a torque of40 Nm (29.5 lb.ft.).NO