Volvo penta outdrive manual

Paint may be obtained from Volvo Penta Parts. Recommendations for Antifouling All antifouling paints that prevent marine growth are poisonous Paints and may harm our marine environment.

Page Storage And Maintenance General Information Contact with bottom paint may cause sever corrosion of the transom and sterndrive assembly. See sections titled Chapter 2. Inspect bellows for wear or leaks. Page Sterndrive Oil Capacity If present find cause and repair before operating drive.

Also check for metal or other debris in oil. If present find cause and repair before operating drive. Quantities provided above are for initial fill of new, empty sterndrive. Page 22 Sterndrive, General Information Remove shift cover. Use 12mm socket, rachet Place a 4 quart or larger drain pan under lower gearcase skeg to catch oil. Clean area around plugs before removing plugs. Debris in oil can damage sterndrive.

Remove oil drain plug. Discard o-ring. Page Filling Sterndrive With Oil When filling drive, proper oil level is determined by filling drive with oil until oil appears at oil level hole on starboard side.

Make sure o-ring is installed and seated correctly on plug. Hand tighten drain plug. Check oil level with dipstick. Oil should show on flat portion of the dipstick. Add oil if required, through the dipstick hole. When oil level is correct; Page Propeller Removal Sterndrive, General Information Propeller Removal A rubber hub in the propeller is the shock absorber that minimizes impact damage to the sterndrive and engine.

If the hub slips, it should be replaced. The hub should be replaced by a reputable propeller shop. Page Dps Sterndrive, General Information Shift the sterndrive into forward to lock the propeller shaft. Use propeller tool or 30 mm socket and rachet to remove rear propeller nut. Remove rear propeller. Shift the sterndrive into reverse to lock the propeller shaft. Page Propeller Installation Sterndrive, General Information Use propeller tool and rachet to remove front propeller nut.

Remove front propeller. Clean the propeller shafts. Inspect for fishing line or other debris; remove if present.

Inspect shaft seals, correct if leaking. Propellers turning with engine power can cause serious injury. Page 28 Sterndrive, General Information Coat propeller shaft and inside of prop hub with grease Future removal of the propeller will be difficult if this is not done. Failure to install all components could result in propeller loss and damage to sterndrive.

Place thrust bushing B on propeller shaft with inner taper toward gearcase. Future removal of the propellers will be difficult if this is not done. Shift the sterndrive into forward to lock the propeller shaft. Install the front propeller. Install the front propeller nut, chamfered edge forward. Page 30 Sterndrive, General Information Torque nut to 45 ft.

Use prop nut tool and torque wrench. Page Anodes Sterndrive, General Information Install the rear propeller nut, chamfered edge forward. Be sure the chamfered edge of the propeller nut is facing forward. Torque nut to 50 ft. Testing Test for proper installation of the anode. Set an ohmmeter to the low ohms scale. Connect one ohmmeter lead to a good ground, and the other to the anode. Use 12mm socket. Remove cover. Remove cube and cable from bracket. Loosen jam nut N.

Thread cube off of cable. Pull cotter pins up and out of housing. Pry in housing slots behind pin heads to start pins, protect painted surfaces from damage by tools. After pin head is exposed, use pliers to pull pins from housing and cylinders.

Disassemble Mount the sterndrive in a suitable holding fixture and clamp it securely. Page Reassemble Sterndrive, General Information Reassemble Mount the lower housing in a suitable holding fixture and clamp it securely. Fixture is not shown in the following images to provide clearer illustration of parts. Lightly oil new seals S and insert in grooves in lower housing.

Also oil o-ring R on retainer. Do not substitute other types of lock nuts for the spiral locknuts. Other nut types will not torque correctly, causing damage to the sterndrive. If spiral locknuts are lost or damaged replace with locknut part number specified in the Parts Catalog. Page Installing The Sterndrive These tools should be used whenever recommended.

Follow the steps and procedures described in this section—in the order listed—to perform a complete installation of a Volvo Penta engine and sterndrive assembly. Prepare for installation 2. Thread lifting eye into oil level dipstick hole. Use a suitable hoist to remove drive unit from work area and holding fixture. Make sure all attaching hardware is readily available.

Page 40 Sterndrive, General Information 5. If the boat transom design requires the transfer of the drive unit from a hoist onto a drive unit cart, do so now.

Remove lifting eye bolt from upper housing. Reinstall dipstick and o-ring. Tighten dipstick. Page 41 Sterndrive, General Information 9. Inspect seal ring for proper fit in its groove. Inspect and lightly lubricate u-joint bellows lip with grease Using handle , slide alignment tool through gimbal bearing.

Alignment tool must easily slide through gimbal bearing and into engine coupler. Apply grease to the six studs. Reinstall the large seal 4 and small seal 5 onto the shift cable. Tilt the trim cylinders up above the upper gear splash plate. Page 43 Sterndrive, General Information 3. To align u-joint shaft splines, rotate propeller shaft s until the shaft splines engage the coupler. Wear gloves or use a shop cloth to protect your hands.

Propeller shaft splines may be sharp. DR 4. Slide sterndrive onto six studs until it is completely seated against the pivot housing. Use the flats on pin heads to align the trim pins with the cotter pin holes in the gear housing. Install the cotter pins. Page 45 Sterndrive, General Information 4. Rotate eccentric piston arm 7 to extend bellcrank.

Move the gear shift to reverse to extend the shift cable. Thread cube halfway onto cable end. Rotate eccentric piston arm back to neutral detent position, then move gear shift to its neutral detent position.

The cube must be securely attached to the bracket and the cable. Failure to secure cable and cube will result in the shift cable coming loose and result in loss of shift control. After shift system tests are performed, all adjustments are made, and after final gear oil level check: Reinstall the shift cover.

Carefully thread five screws in to housing. Use 12mm socket and rachet to hand tighten, then torque to ft. Shim position Vertical shaft 2. Pitot passage Top nut 3. Oil passage Top cover 4. Exhaust passage Dipstick 5.

Water passage Plug, oil drain 6. U-joint View Tool Name Part No. Page Sterndrive Removal And Disassembly Upper Gear Housing Sterndrive Removal and Disassembly To service components of the upper gear housing, remove sterndrive from transom shield and separate upper housing from lower. Follow the procedures in the Sterndrive, General Information chapter of this manual. Attach spline socket to holding fixture Tighten set screw securely.

Remove screw S and washer attaching shift bracket. Remove bracket B and rod. Shift housing is spring loaded and may pop out when screws are loosened. Remove pinion bearing carrier and u-joint using two screwdrivers. Be careful not to damage upper housing or bearing carrier mounting surfaces. Save any undamaged shims, they can be reused. Remove and discard O-ring. Remove and discard cover seal G. Push holding fixture shaft up to engage upper driveshaft splines.

Align flat part of fixture shaft with locking screw. Tighten locking screw to prevent upper drive shaft from turning. Remove Left-Hand threaded top nut with 30 mm socket. Spanner must be updated with new plate , original plate will not mate to housing. Insert tool into housing. Use two upper housing cover screws to secure spring loaded arm to top of gear housing. Page 58 Upper Gear Housing Remove lower bearing and shaft assembly.

Remove and save shims. They can be reused if not damaged. Turn lower bearing and shaft assembly over. Remove O-ring. Push up on shaft to disengage shaft c-clips from spacer. Remove upper driveshaft c-clips and spacer from shaft. Place sleeve , large end up, in a press. Place rag in tool to protect gear.

The universal joint is not servicable. No parts are offered for the u-joint. Testing has shown that when any part of the u-joint fails the other parts are also compromised.

The complete u-joint must be replaced. Pinion Bearing Carrier Disassembly Secure holding fixture in vise as shown.

Page 61 Upper Gear Housing Remove pinion gear retainer screw using 11mm 12 point socket. Discard screw. Remove the pinion gear retainer. Pinion gear screw must not be reused. Proper torque cannot be achieved with a used screw. Carefully remove pinion bearing carrier from universal joint shaft. If pinion bearing carrier is stuck, a press may be used to remove universal joint shaft from pinion bearing carrier. Page 62 Upper Gear Housing Remove pretension sleeve from input gear shaft and discard.

Pretension sleeves must not be reused. Proper rolling torque cannot be achieved with a used pretension sleeve. Turn pinion bearing carrier over and place it on tool. Press large bearing out using tools in previous step. Remove shift shoe and spring. Scrap the O-ring. Pull spring pin out with side cutting pliers.

Fix the pin in a vise. Tap housing with a plastic faced mallet until it comes off pin. Pull eccentric piston out of housing. Page 65 Upper Gear Housing Grease the seal ring, eccentric piston and its seat in the gear shift mechanism. Install the eccentric piston. Make sure not to damage the seal ring. Tap the pin in so far that the milled cutout is level with the hole for the spring pin. All references to gear oil in all assembly steps are referring to the same oil used to fill the drive; Volvo Penta GL5 Synthetic gear lubricant, SAE 75W- Place pinion bearing carrier in press with large opening up.

Page 67 Upper Gear Housing Oil large and small roller bearings with gear oil. Place pinion bearing carrier on top of input gear. Place small bearing on top of input bearing shaft. Press small bearing onto shaft using drift , until all end play is removed.

Always wear eye protection when removing or installing snap rings. Install seal retaining ring in its groove in pinion bearing carrier using retaining ring pliers Make sure retaining ring seats completely. Page 69 Upper Gear Housing Carefully insert universal joint shaft through seal and engage splines of input gear.

Use new screw supplied with u-joint or order new screw from Parts. Page Lower Output Gear Assembly Upper Gear Housing Use prybar or large screwdriver through u-joint and against bolt on fixture to prevent u-joint from turning Install screw, tighten a little at a time using 11mm 12 point socket.

Turn pinion bearing carrier while tightening screw to seat bearings. Frequently remove assembly from vise to check rolling torque. Lightly oil inside diameter of ring with gear oil. Place ring R on top of the sleeve, inner lip down.

Protect gear face. Lightly oil inside diameter of bearing with gear oil. Press bearing in place until it seats, using drift The following procedures will set gear position for the input, lower and upper output gears.

Protect gear cup surface. Place shim tool , on assembly as shown. Apply light pressure to hold shim fixture properly on gear. Fixture should be level across top of gear shaft. Take feeler gauge measurement A at outer, lower edge of ring. Number represents thousandths of an inch 0. For pinion gear, use the following information when adding or subtracting etched allowance figure from dimension D.

Groove must be on same side as bearing. Lower Output Gear Installation Mount upper gear housing on holding fixture Secure housing to fixture with 4 nuts N on studs. Page 77 Upper Gear Housing Place shims on bottom bore as shown. Shims go on surface where bearing is mounted. Re-tighten fixture bolt. Lightly oil retainer ring with gear oil. Page 78 Upper Gear Housing When fully seated, retainer ring will be below bottom edge of pinion bearing carrier opening.

Install spanner wrench , and secure tension arm with two top cover screws. Place shims on upper bore as shown. Shims go on surface where bearing ring is mounted.

Bearing ring sits in machined surface at top of housing. Measure clearance between the top nut and upper gear. Vertical clearance should be 0. If clearance is high, install thicker nut.

Torque screws, in a crossing pattern, to ft. Top Cover Shimming Measure in inches, depth of bearing seat in top cover. Save as measurement D. Torque screws, in a crossing pattern, first pass to ft. Checking Gear Lash This procedure will check the relative clearance between the pinion gear and the upper and lower output gears.

With your finger, gently rotate gear first in one direction until tooth contact is felt, then in other direction. Do not turn gear far enough to rotate universal joint, just far enough to contact pinion gear in both directions. Subtract Subtract Re-shim Re-shim Lower gear less than range min.

Lower gear greater than range max. The contact pattern will give you a visual clue as to where the teeth are meshing with each other. Page Final Assembly Of Upper Gear Housing Upper Gear Housing If the dye pattern shows contact as shown in this picture, shim thickness behind pinion carrier housing must be increased, i. The driven gears must be shimmed inward to maintain correct backlash.

If needed, lightly tap bearing ring to seat it in housing. Be careful not to disturb the shims when installing bearing ring. You may have to loosen the four nuts that secure the upper housing to the holding fixture, to center the housing and shaft. Page 89 Upper Gear Housing Install pinion bearing carrier into gear housing and secure with four screws. Top Cover Installation Make sure correct shims are under cover and shims are positioned correctly. Do not re-use old O-ring.

Install spring and shift shoe in piston. Place shift mechanism in mounting hole. Screw has locking patch, if screw is removed it must be replaced. Torque screw to ft. Metric Bearing retainer ring ft. Propshaft 2. Propshaft bearing housing 3. Seal, propshaft 4. Bearing, propshaft 5.

Water intake Use the same type of screw that was removed if any require replacement. If a socket head screw was removed, a socket head screw must be used to replace it. Insert puller into housing, expand jaws tightly behind bearing cup. Pull up on rod to pull out cup. Propshaft Bearing Removal Screw propeller nut on shaft to prevent thread damage. Remove retainer and o-ring, discard o-ring. Pinion nut removal Screw pinion nut holder, onto handle Slide guide plate over handle.

Insert pinion nut holder in to drive gear. Pull shaft and bearings up by tightening vertical screws. Hold the pinion gear while lifting shaft. Remove pinion gear. Do not remove bearing from propshaft gear unless you intend to replace bearing. Removal process may damage bearing. Use bearing separator to support bearing.

Use drift to press gear out of bearing. Place all rollers in bearing case. Tool presses on rollers. Install remover into pinion bearing. No service is needed and the magnet should not be removed during routine gearcase service. If the magnet is removed, when reinstalling, torque screw to ft. Propshaft Bearing Apply gear oil to inner diameter of bearing. Slide bearing on shaft with taper facing prop end.

Place bearing installer N on open jaws of a press support. Slide bearing on shaft with taper facing away from small bearing. Place bearing installer on open jaws of a press support. Position raised lip of installer up; it must contact nose of bearing.

Measure between inner ring of fixture and horizontal gear surface. Average feeler gauge readings. Place installer on cup. Place smallest step of plate in retainer bore. Volvo Penta 3. Volvo Penta 4. Volvo Penta 5. Volvo Penta is a Swedish company, part of the Volvo Group, a manufacturer of marine and industrial engines.

There are two versions of the appearance of the name Penta. According to one version, five people took part in the development of the first engine. On the other - only the fifth set of drawings was approved for the creation of a motor in the gland.

Penta's engines quickly became popular. In , Penta received an order for the supply of engines for the production of the first Volvo car. Volvo Penta supplies engines and power plants for pleasure boats and yachts, as well as boats intended for commercial use "working" boats and diesel power plants for marine and industrial use. The engine range consists of diesel and gasoline components, ranging from 10 to 1, hp. Among the company's innovations in the field of shipbuilding are a tilt-turn column and Duoprop counter-rotating screws.

In recent years, Volvo Penta has proposed a new propulsion system with pulling screws and a joystick to control it. Douglas Ventura Wednesday, 05 January Bruce Young Friday, 08 October Nebojsa Tuesday, 21 September My email adres : nebojsa. Sergei Wednesday, 15 September Benjamin Sunday, 29 August Manuel Saturday, 21 August Simon Peco Thursday, 19 August I'm looking for the wiring diagram for a Volvo Penta 5.

Ivan Tuesday, 17 August WE have a Volvo Penta D marine engine with saildrive. Looking for a service and parts manual. Appreciate your assistance. Daniel Wolf Sunday, 18 July I love and appreciate the way people provide info like this - it's an inspiration. I wonder if anyone has a manual for a D Brand new in my boat but with no instructions. I'm hooking it up so some installation instructions would be nice too, though that's pretty much done it would be nice to catch any mistakes.

Nicolae Burlacu Tuesday, 06 July Fernando Gomes Santos Tuesday, 06 July Good morning Where I can download the service manual for D6 marine engine? Can you send it to me? Best regards Fernando. Bruce Meyer Wednesday, 02 June This manual says engish but is not? David Irwin Sunday, 30 May Phillip Wednesday, 31 March Please email: plegare flash.

Many thanks! Richard Mortimore Friday, 26 March I have installed a Volvo d marine engine to my Yacht. Do I need to fit an electrical regulator say a Belmar etc or does the fitted alternator supersede this activity? Filipe Sunday, 28 February Boa Noite, preciso do manual de montagem da. Andrey Alexeenko Friday, 05 February Kind regards, Andrey admin downundersubmarines.

Good afternoon, looking for a repair manual for volvo penta d3.