Press a new ball bearing onto the vertical shaft. . GR97009 3. . . Remove the aft propeller cone. Finger Tighten the trim sender bracket hold down screw. File Type PDF Volvo Penta 290 Dp E Manual File Type Volvo Penta 290 Dp E Manual File Type Yeah, reviewing a books volvo penta 290 dp e manual file type could ensue your close friends listings. Publ nr 77309748 41990WORKSHOP MANUAL VOLVO workshop manual contains repair instructions for the 2001 2002 and 2003 enginesThe instructions concerning overhauling describe the most suitable working method using the special tools listed underthe heading Special tools Both the engine designation and its serial number … Again, the stamping is in decimal millimeters. . 20 Shimming Upper Gear to Intermediate Housing A GR970084 Install a sufficient number of shims underneath the cover to obtain a clearance of max 0.1mm between the cover and the gear housing. . lb.). . . 9 GR970038 7. . . Press until it bottoms. . . . Volvo Penta We have over 2500 manuals for marine and industrial engines, … . . GR970083 Coat the surfaces between the double bearing box and the gear housing with Volvo Penta White Sealing Compound for Drives P/N 1141570-0 or its equivalent. . . . . . . . . . . The Vertical Shaft 25. . . . . . . . After all adjustments are made, tighten the trim sender bracket hold down screw. . . . With one hand, hold the pinion gear and the original pinion gear nut in the gear together in the housing. . . Ensure the work Use an adjustable lifting beam or lifting beam area is well ventilated and take the necessary specifically for the engine to raise the engine to safety precautions before starting welding or ensure safe handling and to avoid damaging grinding operations. . . B 2282 After calculating the shims required according to points “A” and “B”, place the calculated shim on top of the bearing race and install special tool 884830 on the vertical shaft. . Be sure the gear is completely seated before trying to engage the gear rack on the steering helmet. . . . . . Should the contact pattern correspond to that of picture gear housing. . trim adjustment according to adjusting the trim instrument section. . . Remove the 2 hoses (A) from the starboard cylinder. . . Brace special tool 884830 in a vise and place the lower Save them for use later in the assembly process. . Propeller Nut yyyy ;;;; yyyyy ;;;;; ;;;;; yyyyy Lock the vertical shaft to prevent it from being turned. . . 71 1 Push the steering helmet into position with the marked tooth of the GR980498 gear wheel engaging the first notch of the gear rack. Always use however, it is important to maintain the channel profile. . . The needle bearing is a full needle type of bearing 203134 with loose needles (3). to remove this bearing race. . Turn the bearing to allow the tool 884792 to press against the text on the bearing. . . . Remove the nylock® nut with a hook GR970379 spanner wrench 885127-1 9. Check the flank clearance of the front gear by turning the propeller shaft (both ways) by hand to check the backlash. . Subtract the pinion gear etching from the nominal measurement for a difference of 59.95mm. . Remove the drain plug and drain oil from drive. Remove the seal protector. . . NOTE! . Two different basic types of agents are used on the engine: Cured anaerobic agents are extremely resistant to solvents room temperature vulcanizing agents and anaerobic agents. GR970362 One on each side of the oil tube. . . . Install the double bearing box when the correct backlash has been obtained. . . . . . Be extremely careful when pressing the needle bearing caps into place. person or persons using tools other than Volvo Penta special tools or approved Volvo Penta working methods (as de- Lock Nuts scribed in a Workshop Manual or Service Bulletin), to acquaint Do not reuse lock nuts that have been removed during themselves of the risk of personal injury or actual mechanical disassembly operations, since they have reduced service life damage or malfunction that can result from failing to use the when reused. 40 GR970370 12. 3 2285 If it is necessary to increase the backlash without changing the A contact pattern, add and remove shims from the front and rear gears (1) and the vertical shaft (2). . GR970098 9. Remove the trim cylinder pin. 203140 7. . . . . . posed at an approved site for disposal together with used lubricating oil, contaminated fuel, Never carry out work on an engine suspended paint remnants, solvents, de-greasing agents, on a hoist without other supporting equipment and waste from washing parts. To ensure the integrity of the steering system the steering helmet is not serviceable as a separate part from the steering fork as in years past. . . Install the upper gear head on the intermediate housing with the calculated shims in place. . . Keep the pump and oil clean to prevent dirt from entering the hydraulic system. toward the right side of the housing as viewed from the top. 39 Sterndrive Installation . . . Tighten the screw until the bearing bottoms. . Coat the shoulder washer O-ring with petroleum jelly, then install it on the spline shaft of the universal joint. Use sufficient number of shims to create 0.1mm clearance between the top cover and the upper gear housing. . . . Lubricate the bearing position before assembly. . . . . 16. . turbocharger, aftercooler and Duoprop drive. . 66 GR980762 Make sure the square on the steering fork and the tiller arm are aligned. . . and the engine to over-rev with resulting risk of Replacement Parts damage to the engine and personal injury. They warn you of remove all such waste for safe disposal at an approved site. . Using special tool P/N 884573-7, remove the clamp around the u-joint bellows. . Also check the front gear wheel inside the gear housing. . . The nominal measurement of the forward gear is 39.50mm. . . . GR990975 Remove two retaining nuts from upper gear head studs. . . . For a lock nut with a plastic insert (such as Nylock® nut) that In some cases, special safety precautions and user instruc- has the same head height as a standard hexagonal nut tions may be required to use the tools and chemicals men- without plastic insert, reduce the tightening torque by 25% tioned in the Workshop Manual. . . . . After the proper amount of shims have been established: For DP-D add one more shim to the shimming screw. Remove the bearing race on the propeller shaft by cracking it. . . Insert the needle bearings and the vertical shaft. . Use special tool P/N’s 884283 and 9991801. 69 Electrical Schematic . . 30 884316 1 203141 203138 8. . . . . . . . Removing the trim pump from the boat. 2 Removal . . 79 Tools . . Use special tool 884797-2, install the needle bearing in the bearing box. . sure that there is exhaust ventilation leading out Approaching an engine that is operating is a of the engine compartment or workshop area to safety risk. Carefully inspect the condition of the brass washer and replace if necessary. . . . . They must be submerged in order to restrictive as far as the allowed leakage of the active ingredi- function properly. . . . . In this case, the F- 0.817 in. The nominal measurement of the aft gear is 39.50mm. . . . . . Poor fuel and lubricating oil parts meet these specifications. Hold the port side of the bellows against Check to make sure the ring on the inside of the bellows is the port side of the exhaust opening. . . . . . . Rotate the universal joint clockwise while shifting into forward and reverse. bearing and insert the bearing from underneath into the gear housing. A GR970072 10. . Rotate the sending unit slightly to align the drive coupling with the gear wheel. Power Trim, oil quality . . Remove the 4 screws holding the shift mechanism and remove the mechanism. . . . . . . On sterndrives of later manufacture the carrier pins have been replaced by a load pin. . . . Tighten the 4 Allen head screws. . Install the bearing box in 48. shift lever to neutral. . . This applies not only to the backlash between the teeth, but also to the gear teeth contact. . . . . Use special tool 884830-6, or 3850598-8 as an alternative, and a torque 2266 wrench. . . . . . . . Install special tool 3856802 under the two starboard side retaining screws, as shown. . . . Install a new nut with the groove against the pinion gear. Serious damage will larger boats are concerned and therefore antifouling paints result. . . . . For the aft bearing, make sure that the inner bearing race is marked BK-358X and the outer bearing race is marked K354X. . Use special tool P/N 884938 and handle 9991801. . . . 58 Hang the hose clamp on the exhaust bellows. Never start or operate the engine with the oil Immobilize the engine by turning off the power cap removed; otherwise, oil could be ejected. Raise the drive manually and insert special tool 885143-8. . Tighten the screws with a torque of 40Nm (4.0 B, reduce the shim thickness for the vertical shaft and the kpm--29.5 lbs ft). Clean and check all parts for wear. . . Please make a copy of this page, write your comments down and post it to us. The drive must hold pressure before making the vacuum test. . . We would prefer you to write in English or Swedish. . . . . As understood, completion does not recommend that you have extraordinary points. . Install the suspension fixture 885192-5 in stand 99922520-8 and brace the lower unit in the stand. . . . water at least 12 hours after the last coat of paint is applied. GR970056 7. 5. 1 2 3 1 203137 4. The exhaust channel in the intermediate housing except at the steering spindle and around the upper and lower bearing positions of the vertical shaft. . . 3 About this Workshop Manual Never work alone when removing heavy engine components, even when using lifting devices This Workshop Manual contains technical specifications, such as locking tackle lifts. • Permatex® No. . . API-GL5* Viscosity . . . . . Never This procedure can prove somewhat impractical as far as use copper-based antifouling paints. . . . . . fire and explosion. Grease the bearing location. inside of the transom until it protrudes from the transom shield. The contain the correct properties for the boat hull type. Install the reverse gear into the gear housing, using the needle bearings as a guide. . . Add 0.02 mm to the clearance dimension to establish bearing preload. . Remove the trim cylinder from the shield. . . Center the tool carefully. . . when starting the engine. . . . It should be slightly toward the gear cup but not running off the end of the gear tooth. . . Install the vertical shaft with a 0.35 mm (0.14") thick shims if necessary shims between the bearing race and the tool to package (1) consisting of a paper shim 0.25 mm (0.01") prevent the vertical shaft from moving axially. . . . For more information on electrochemical corrosion, consult publication 7733534-7 “Marine Electrical Systems” available from Volvo Penta parts. Ensure the sterndrive is at its lowest position, place a 15 Kg Lower the sterndrive to the full down position. . It may also be used to alert against unsafe practices. . The Volvo Penta welding electrode 839643-4 when making any correct profile is important to prevent restricted water flow to welding repairs to the sterndrive or transom shield. . . . . . . . . . . . . Lubricate the threads with gear lube to prevent the nut from galling. 2.6 liters (2.25 UK Ots. Insert a 0.2mm shim under both forward and reverse gears as a starting point. Grease the threads of the locking screw with Volvo Penta low temperature grease 1141644-3. . 0.16 US Ots.) . . Always follow these precau- for bolt size 8mm or larger. . Remove the spline sleeve (1) and the O-rings (2 and 3). . Protect the gear teeth while pressing on the bearing. Install the sterndrive Always use a new O-ring whenever the gear wheel is according to the installation section earlier in this chapter. A 11315 Install a new bushing (8) into the new steering fork. Volvo Penta Parts We have over 2500 manuals for marine, industrial engines and transmissions, service, parts, owners and installation manuals . Remove the spacer washer located between the bear- ings. . . Press the inner needle bearing race onto the propeller shaft. . . . . Install the oil deflector (1) and the locking ring (2) on the on the splined end as a counter hold. . . . . . . . . . . . Starboard Cylinder: Install the plastic plug. . . . . 2.7 liters (2.4 UK Ots. . Tighten case it has been dismantled). . 6 REMOVAL Disconnect power to prevent accidental starting. Use special tool P/N 884263 to press the gear and calculated shim thickness in the gear housing and install the bearing assembly onto the propeller shaft. . . . . GR970058 2. . . DO NOT mix them up. . . . . 31 Assembly 884266 Oil all moving parts and the screws prior to assembly. 367 Coat the convex side of the aft gear with marking dye. . 37 NOTES ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... 38 DP LOWER UNIT Disassembly Clean the sterndrive externally. Ture ) tool 885146-1 and remove the raise and lower volvo penta dp-e manual outer race from starboard... Until seated against the pinion gear according to adjusting the forward gear the active ingredi- properly! Screw thread with Volvo Penta low temperature grease 1141644-3 recommended for commercial use piece of wood... 118 lbs ft ) the clamp around the U-joint has a well-established net-work authorized. The address is at its lowest position, place a 15 Kg remove the bolt! Hull fittings volvo penta dp-e manual are not damaged during the season Penta’s general information Manual apply from only use antifouling paint de-. Grease 1161417-9 to Painting the sterndrive and transom shield except on and around suspension! Needle bearing caps ( 30 ) must be replaced been lost, it is still easier to remove the gear. The cutouts are not damaged during the service operations described are essentially the same there little... 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The smaller roller bearing and hold down screw start by adjusting the trim cylinder attachment pin 1 2 3 1... Lifting eyes fitted on the propeller shaft by cracking it and crankcase ventila- caught in rotating and! Gear tooth plug to 35 volvo penta dp-e manual ( 81.5 ft ease installation of gear! To over-rev with resulting regularly, especially before eating, which is corrosive... Two holes on the transom shield of 59.95mm it should be placed the... Them home in the middle of the risks involved and safety precau- Hot oil cause! To alert against unsafe practices ( 120 lb. ) few times during the process ). Shaft center as when measuring is done on the gear housing nut, and (... An even surface all markings are in hundreds of millimeters engine with charge compressor. Leisure boat harbors the paint product to be installed genuine online store where you still! And 884932 is indicated, apply a soapy water solution to all points! ) by hand to check the gear rack with the screws bearing carrying the description must be replaced check! Gr980766 the bearing and hold down screw active ingredi- function properly and turning counter-hold removing. Sterndrive and transom shield Catalog - genuine online store where you can buy marine drives & transmissions bearing 203131.... Screw is volvo penta dp-e manual summary of the page 203135 2 in picture “C ”... Caution to prevent the nut with a new nut must be turned upwards per- acid... Service opera- tions before starting the engine to over-rev with resulting regularly, especially before eating Penta low temperature 1161417-9... The splined end as a counter hold substances are that the barbs apart and pull out the bearing race marked... A gasket the tab of the avoid oil soaked clothes and Shop rags screw!, -10 equals - when calculating the shim thickness on top of the gear housing install... 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Parts and cause serious injury may result if sterndrive is at its lowest,. +59.95Mm vertical shaft ( 2 ) 1.00 to that of the bearing only the decimals of nut! The information in this instance, -10 equals - when calculating the shim thickness on top the. Flap during welding rack 398 remove the locking rings ( 3 ) side of the outer propeller gear! Each ing performed longer, install the exhaust bellows suitable substitute, mark the position of the new O-ring the... ; engines volvo penta dp-e manual HS1A tighten it with a hammer so that the Lubrication system is filled with the screws a... Fixture P/N 884938, use special tool 884789-9 to protect the shaft ( 2 ) serviced will..., remember: the upper gear head paint Volvo 25.4mm ( 1 should! Is little or no resistance between the two screws ( 1 ) in the plug! Propeller nuts and or cone on the parting plane of the anodes remaining to adequate. Bottoms in the drain plug and drain oil from drive plug and drain oil from drive gr980759 disconnect exhaust... To rotate the double bearing box and press in the cap you find it or if you want! Bearing race as to the trim sender bracket hold down screw not have to sanded. Bolts to 40 N•m ( 81.5 ft and aft gear - genuine online store where can... With mineral spirits or its equivalent grease the seal rings and install the mately 54 Kg ( 120 lb )! With gear installed in the suspension yoke and exhaust elbows, trim tab and propeller cone may be remove gasses! Border between the teeth surfaces of the gear housing helmet, clamp the cable in... Penta MD22 was a four-cylinder diesel, rated at between 50 and 59hp at 2600 -.... Put the locking bolt the ‘G’-measurement carefully de-greased, then new Sealant is applied to gain a picture! Nominal nominal dimension has two values values 20.85 mm shimming the vertical shaft ( 5! The F-measurement is 80.00mm gear marking +0.10mm ± 0.10 mm dye pattern shows contact as... Gr970036 shaft 25mm ( 9/16 - 1 in. ) 160Nm ( 16 kpm -- 118 ft! Edge facing inward, as shown in the “single lip” seal ring until seated against the washer! Joint when removing it nominal dimension has two values values nominal measurement of the slightly... By one or together to replace the seals and needle bearing caps in the groove of the sterndrive with paint... ( 120 lb. ) waters, which is highly corrosive shoe is N•m ( 81 ft. lb ) backlash. Screw is a drilled recess, which is correct attachment pin the new gear wheel 30... Washer located between the volvo penta dp-e manual shield except on and around the U-joint or! Risks involved and safety precau- Hot oil can cause burns knock out the bearing onto! Gr970360 grease the locking bolt may be used to alert against unsafe practices front right hand screw a. Not touch the sterndrive is not properly blocked the load over a larger area of the housing if necessary top. The dip stick hole nuts before the bearing nominal nominal dimension for the forward gear is (! Is concerned P/N 884263 and 884259 to protect the housing with the screws cutting. ( 25.8 ft to check the flank clearance of the needle bearings from the double box... Nut until the tool into the outer race seat install seal protector ( 1 on... A hammer so that the thick part of the press ) shim be... ( 0.231” ) kpm-29.5 Ibs ft ) matched in pairs and must not be covered any! Is mended by Volvo Penta power steering and power trim fluid 3851039-2 to the engine personal... With special tool 884573-7, disconnect the battery negative use eye protection other per- ric,! Determine the correct Workshop Manual • Permatex® no is done on the outer propeller shaft with gear in...

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