Volvo Penta AQUAMATIC 280 Workshop Manual Download

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Special tools

3855876

9991801

3810105-1

Pin installer, intermediate

3810152-3

Drive pressure tester

3850598-8

Spline socket, upper & lower

3850608-5

Snap ring plyers, upper

3855876-3

Tool, new type of propeller nut

3856761-6

Holding plate, shift mechanism

3858578-2

Drive vacuum tester

9985494-5

Spring gauge/scale, upper

9991801-3

Standard shaft

9992520-8

Stand

3858578

Chemicals

Volvo Penta
part no.:

1141570-0

Sealant for drives

1161053-2

Thread locking compound

1161099-5

Sealing compound

1161351-0

Bushing installation adhesive

9985494

9992520

3810152

3850598

3850608

3856761

3810105

Summary of Contents for AQUAMATIC 280

Page 1: ......

Page 2: ...Drives Workshop Manual 2 0 B C 280 280 DP 285 290 290 DP SP A SP C DP A DP B DP C ...

Page 3: ......

Page 4: ...P A SP C DP A DP B DP C Contents Reconditioning the universal joint 62 Reconditioning the shift mechanism 64 Types of shift mechanisms 64 Shift mechanism type 1 64 Shift mechanism type 2 66 Shift mechanism type 3 68 Intermediate housing 73 Reconditioning the intermediate housing model 280 285 and 285A 73 Assembly 75 Reconditioning the intermediate housing model 290 and 290A 77 Assembly 79 Recondit...

Page 5: ...system gear rack 151 Changing the trim system gear wheel 153 The power trim pump 155 Removing the trim pump from the boat 156 Removing the oil reservoir 156 Replacing filters 156 Removing the electric motor 157 Installing the elctric motor 157 Replacing adapter and pump assembly 157 The relief valve assemblies 158 Installing the trim pump in the boat 158 Venting system 158 Test 158 Adjusting the t...

Page 6: ...bjects in the inlet pipe can also damage the machine Never use starter spray or the like Explosion risk in the inlet pipe Risk of personal injury Avoid opening the coolant filler cap when the engine is hot Steam or hot coolant can spray out and built up pressure will be lost Open the filler cap slowly and release the overpressure in the cooling system if the filler cap or cock must be opened or if...

Page 7: ... injury Risk of blood poisoning All fuels in similarity with chemicals are inflam mable Make sure that naked flames or sparks cannot lead to ignition Petrol certain thinners and hydrogen from batteries are ex tremely inflammable and explosive when mixed with air Smoking is prohibited Ventilate well and take the necessary precautions before conducting welding or grinding work in the im mediate vici...

Page 8: ...en lifting equipment is used one to handle the equipment and one to make sure that com ponents are not damaged When working on board a boat always make sure in advance that there is sufficient space to allow dismantling in situ without the risk of personal injury or dam age to materials WARNING The components in the electrical system and in the fuel system on Volvo Penta products are designed and ...

Page 9: ...ive designation and the PZ number in all correspondence The Workshop Manual is primarily produced for Volvo Penta service workshops and their qualified personnel It is therefore assumed that persons using this manual have a basic knowledge of marine drive systems and can perform the relevant work of a mechanical and electrical nature Volvo Penta continuously develops its products and therefore res...

Page 10: ...ing in since this can result in malfunction or reduce the life span of the re pair Our joint responsibility Every engine consists of a large number of co ordinat ed systems and components The deviation of one component from the technical specification can dra matically increase the impact on the environment from what is otherwise a good engine It is therefore ex tremely important to maintain the g...

Page 11: ...be handled normally Angular torque For angular tightening the screw union is first tight ened with a given torque after which tightening con tinues at a predetermined angle Example for 90 angular torque the union is tightened an addition turn after the given tightening torque has been achieved Lock nuts Dismantled lock nuts should not be reused but re placed with new ones since the locking propert...

Page 12: ...of gasket joints or applied on gaskets RTV compound is clearly visible when the part has been dismantled and old RTV compound must be removed before the union is sealed again The following RTV compounds are mentioned in the Workshop Manual Volvo Penta part no 1161099 5 alternative Permatex no 3 Old sealant is removed with denatured spirit Anaerobic compounds These compounds harden on the absence o...

Page 13: ...gs inter mediate 884143 91 Standard handle pointed lower and in termediate 884161 1 Tool to remove propeller bearing and low er intermediate shaft 884168 6 Bearing press drift upper intermediate and lower 1 Used together with special tools 884281 884140 and 884381 884241 1 Tool to install the needle bearing of the vertical shaft lower 884259 3 Drift bearing installer remover interme diate 884263 5...

Page 14: ...al shaft 884381 5 Dismantling tool for vertical shaft needle bearing 884385 6 Installation tool vertical shaft needle bearing 884386 4 Sleeve dismantling and installing gear wheels in upper gear 884387 2 Attachment plate for upper gear housing 884483 9 Clamp bolt for the collarring of the double bearing box 884502 6 Alignment wedge engine to transom shield 884521 6 Tool for installation of sterndr...

Page 15: ...ket vertical shaft 884831 9 Press fixture bearing race remover low er 884832 7 Drift set tube gear race remover lower 884874 9 Support dismantling the sterndrive from the transom shield 884932 5 Disassembly tool for the outer bearing races of the double bearing box 884933 3 Assembly tool for the outer bearing races of the double bearing box 884936 6 Yoke holding the sterndrive while install ing th...

Page 16: ...in remover intermediate 885149 5 Drilling jigg duoprop lower 885152 9 Kit containing tools 884387 and 885153 885153 7 Spacer ring mounting plate upper 885192 5 Suspension fixture 885197 4 Tool duoprop threaded screw lower 885207 13 Hook spanner power steering cylinder 885208 93 Hook spanner power steering cylinder 885209 73 Sleeve power steering cylinder 885226 1 Drift bearing remover lower 885227...

Page 17: ...type of propeller nut 3856761 6 Holding plate shift mechanism 3858578 2 Drive vacuum tester 9985494 5 Spring gauge scale upper 9991801 3 Standard shaft 9992520 8 Stand 3858578 Chemicals Volvo Penta part no 1141570 0 Sealant for drives 1161053 2 Thread locking compound 1161099 5 Sealing compound 1161351 0 Bushing installation adhesive 9985494 9992520 3810152 3850598 3850608 3856761 3810105 ...

Page 18: ...AQ285 AQ 285A Electro mechanical tilt Powersteering Oil Sameasengine Qty 2 6 liters 2 74 qts Ratio 1 61 1 Drive models and generations AQ 280T Oil Sameasengine Qty 2 6 liters 2 74 qts Ratio 1 61 Power trim tilt AQ 280 Oil Sameasengine Qty 2 6 liters 2 74 qts Ratio 1 61 1 1 89 1 2 15 1 ...

Page 19: ...Prop shaft with nut Gears Line cutter Oil Sameasengine Qty 2 6 liters 2 74 qts Transomshield Doublebearingbox Hook up fork Oil 1 API GL 5 SAE 90 Qty 2 7 liters 2 85 qts Ratio 1 95 1 2 30 1 AQ 290 DP AQ 290A DP AQ 280 DP Oil 1 API GL 5 SAE 90 Qty 2 7 liters 2 85 qts Ratio 1 95 1 2 30 1 Ratio 1 95 1 2 30 1 Dual hydraulic cylinders Oil 1 API GL 5 SAE 90 Qty 2 7 liters 2 85 qts AQ 280 DP PT 1 NOTE If ...

Page 20: ... 95 1 2 30 1 Oil 1 API GL 5 SAE 90 Qty 2 7 liters 2 85 qts DP A1 Ratio 1 78 1 1 95 1 2 30 1 Oil 1 API GL 5 SAE 90 Qty 2 7 liters 2 85 qts Sliding sleeve brass Cover Ballbearing Universal joint Splinesleeve Intermediate shaft Intermediatehousing Nut intermediate shaft DP A2 Sliding sleeve steel Cover Gear set Oil Fully synthetic API GL 5 SAE 75W 90 Qty 2 7 liters 2 85 qts Ratio 1 78 1 1 95 1 2 30 1...

Page 21: ...niversal joint Intermediatehousing DP C Sliding sleeve steel Cover Intermediatehousing Hydraulic cylinder Hook up fork Transomshield Oil Fully synthetic API GL 5 SAE 75W 90 Qty 2 7 liters 2 85 qts Ratio 1 78 1 1 95 1 2 30 1 DP C1 Propeller shaft Propellercone Oil Fully synthetic API GL 5 SAE 75W 90 Qty 2 7 liters 2 85 qts Ratio 1 78 1 1 95 1 2 30 1 ...

Page 22: ...rd reverse cone 10 Upper gear housing 11 Coupling box 12 Shift mechanism 13 Shift plate 14 Vertical shaft 15 Intermediate housing 16 Trim tab 17 Circulation pump 18 Propeller shaft 19 Propeller shaft gear 20 Water intake 21 Lower gear housing 22 Retaining pawl 23 Exhaust bellows 24 Transom shield 25 Supporting rubber cushion 26 Drive shaft 27 Damper plate 28 Flywheel Design and function Model 280 ...

Page 23: ... 6 Universal joint 7 Input gear 8 Forward reverse gear 10 Upper gear housing 11 Shift mechanism 12 Shift plate 13 Vertical shaft 14 Intermediate housing 15 Trim tab 16 Porpeller shaft gear 17 Outer propeller shaft 18 Inner propeller shaft 19 Lower gear housing 20 Water intake Models 290 DP DP A DP B DP C 2 1 3 4 6 5 7 8 10 11 12 13 14 15 16 17 18 20 19 ...

Page 24: ... propeller of the Singleprop sterndrive according to the picture 2 Remove the propellers of the Duoprop sterndrive according to the picture The picture shows the earlier model NOTE Never mix propellers from different drives A propeller B propeller A B Alt 2 Alt 1 ...

Page 25: ...n remove the shift cable locking plate 2 5b Sterndrive model 290 Remove the cover over the shift mechanism and disconnect the shift cable from the shift plate and remove the swivel Remove the screws holding the locking plate then push the locking plate down 6a Sterndrive models 280 and 285 IMPORTANT Carefully check the rubber bel lows for possible damage and also check that the hose clamps are pro...

Page 26: ... retaining pawl 1 by hand downwards and lift the sterndrive also by hand to its fully raised po sition Hold the sterndrive in this position while in stalling the suspension tool 2 as indicated in the picture NOTE Do not overload the suspension tool by for example standing on the raised sterndrive It is also possible to raise the sterndrive by operating the sterndrive tilting motor sufficiently to ...

Page 27: ...ng screws holding the shaft journals in the tran som shield Support the sterndrive from underneath and pull out the shaft journals using special tool 884874 A brass drift can also be used Lift off the sterndrive and place it in a suitable cradle NOTE Always replace the bushings 1 8b Sterndrive model 290 Remove the two locking screws holding the shaft journals in the transom shield Support the ster...

Page 28: ... to prevent accidental starting 2 Move control to reverse 3 Loosen propeller cone lock bolt Remove the aft propeller cone 4 Move control to forward gear 5 Remove the aft line cutter forward propeller nut and forward propeller Return the shift control to neu tral Models SP and DP ...

Page 29: ...e shift cable 9 Remove the two screws 1 holding the steering pin to the upper gear head 2 Using two M6 screws 3 30 mm or longer install into the threaded holes of the steering pin As the screws are turned in the steering pin will be forced out of the steering pin socket and steering helmet bushing 10 Using special tool 884573 remove the clamp around the u joint bellows 1 3 2 884573 ...

Page 30: ...l 884573 disconnect the exhaust bellows 13 Remove the clamp on the raw water hose Re move the raw water hose Remove special tool 885143 and carefully lower the drive 14 Remove the hook up fork pin lock bolt Using Pin removal tool 885148 pull the pin half way out of the transom shield WARNING Do not remove the pins completely the sterndrive will fall off the boat 885143 885143 884573 ...

Page 31: ...28 Removing the sterndrive 15 Install special tool 885146 and remove the stern drive from the transom shield 885146 ...

Page 32: ... drain plug 1 and drain oil from drive Reinstall the drain plug after the oil has drained 2 Remove cotter pin and washer from gear shift link age and remove the linkage 3 Remove two retaining nuts from upper gear head studs Removal 4 Remove two allen head retaining bolts Remove the gear head 1 ...

Page 33: ...case neither the gears housing nor the bearings need to be replaced In this case the same shim thickness is to be used 3 Remove the 7 screws holding the lower gear hous ing to the intermediate housing Use a rubber mallet and knock the housings carefully apart Lift off the splines sleeve 1 NOTE On sterndrives of later manufacture the 4 big ger sized screws are installed with stainless steel washers...

Page 34: ...sm and remove the mechanism NOTE Be sure to remove the shift shoe 1 with the shift mechanism 6 Remove the 4 Allen head screws holding the clamping ring 1 and pull out the universal joint and the double bearing box NOTE Take care of the shims 2 7 Remove the 4 screws holding the gear housing cov er and remove the cover NOTE The front right hand screw 1 is a hollow screw with an O ring seal Take care...

Page 35: ...washer 2 Mark the gears to ensure the same location when as sembling NOTE Handle the engagement sleeve and gear wheel cones with utmost care to avoid scratching them 11 Remove the needle bearings 1 and the spacer rings 2 from the upper and lower gear sets NOTE The needle bearings are matched in pairs and must not be mixed 12 Remove by pressing out the upper and lower of the bearing sleeves Use spe...

Page 36: ...ools 884386 and 884265 14 Remove the Allen head screw 1 and the collar washer 2 in the center of the universal joint shaft Pull out the universal joint and push out the double bearing box 3 from the clamping ring 4 Use a rubber mallet if necessary NOTE Do not damage or lose the shims 15 Remove the collar washer 1 from the double bearing box NOTE Take care of the shims 2 Input gear Double bearing b...

Page 37: ... changed separately When changing the out er races of the bearings these must be knocked off Knock evenly all around Always replace the oil deflector washer together with the outer races Wash the parts and check for wear Replace parts when necessary NOTE Gears with cones are sold in sets in order to obtain the correct gear contact ...

Page 38: ...D between the edge of the double bearing box and the edge of the gear Then calculate the difference 2 Install the input gear 1 in the double bearing box 2 and press on the smaller roller bearing 3 in a way that a slight prestressing is obtained Use special tool 884263 NOTE Protect the tips of the gear teeth 1 Press the larger roller bearing 1 onto the gear 2 Use special tool 884263 Assembly models...

Page 39: ...double bearing box again with the screw and the special tool 884483 and check the pre stressing Forward and reverse gears 7 Lubricate the bearings 1 and press the bearings into their respective bearing boxes 2 NOTE Turn the bearings with the recesses in the bearing races 3 for the assembly of the balls fac ing away from the gear wheels Use special tool 884168 Then press on the bearings and the bea...

Page 40: ...l value for both B and C is 61 00 mm 2 40 Add this value to the value stamped into the gear to calculate shims for the forward and reverse gears The shim calculations can be seen in the example be low Measurement A 62 05 mm Fixed Dimension 0 05 mm Gear Etching 1 62 10 mm C Stamping 61 78 mm Stamped 2 0 32 mm 0 013 The shim thickness for the forward gear is 0 32 mm 0 013 The shim thickness for the ...

Page 41: ...s a guide Method 2 NOTE When calculating the shim thickness for the forward and reverse gears remember The upper gear housing nominal dimension has two values If the stamped number is 50 or more use the lower nominal value 61 00 mm If the stamped number is 49 or less use the higher nominal value 62 00 mm Example Stamping 50 or more C stamping 78 00 78 mm Use Nominal Dimension 61 00 mm 61 78 mm Exa...

Page 42: ...ed 17 Install the clamp ring and the cover with sufficient number of shims to ensure a proper compression of the bearings There must be a clearance 1 between the housing and the clamp ring See also the picture under point 19 18 Install a dial indicator to measure backlash The correct backlash should be 0 15 0 25 mm 0 006 0 010 Should the backlash be too small more shims must be added between the d...

Page 43: ...rface thus giving a picture of the width and location of the teeth contact 21 Dismantle the gear set and compare the contact pattern to that of the picture A This picture shows the desired pattern for the drive side of the forward and reverse gear The drive side is the convex side of the gear The dye pattern should be nearly oval in form and be positioned half way up on the gear tooth It should be...

Page 44: ...he spring Feel by hand to make certain 23 If the dye pattern reflects a contact pattern as shown in picture C the shim thickness underneath the drive gear double bearing box must be increased The drive then moves away from the center NOTE If the drive is moved in or out respectively also the gears must be moved in or out in order to maintain the correct backlash Having obtained the correct backlas...

Page 45: ...E Carefully inspect the condition of the brass washer and replace if necessary 5 In order to obtain the correct axial shaft clearance there are 3 left hand threaded nuts 1 with different steps available Select a nut and tighten it tightening torque 120 Nm 88 5 lb ft Use special tool 884830 as a counter hold NOTE Lubricate the treads to prevent the nut from galling 6 Measure the clearance between t...

Page 46: ...004 between the clamp ring and the gear housing Push the clamp ring into its position by hand and use a feeler gauge and measure the clear ance all around 8 Remove the recessed washer and the shims in it Press the new sealing ring against the collar in the double bearing box with the open part against the bearing Use special tools 9991801 and 884312 9 Install the locking ring 1 and the recessed wa...

Page 47: ...x no 3 on the surfaces between the clamp ring and gear housing Install the double bearing box along with the universal joint in the gear housing The guide pin in the double bearing box should be turned downwards Lock the screws with thread locking compound Volvo Penta part no 1161053 2 and tighten them with a torque of 35 Nm 25 8 lb ft If necessary recondition the universal joint See chapter Recon...

Page 48: ...that the sealing for the front right hand screw aligns with the corresponding recess in the cover 15 Install the calculated number of shims and tighten the cover NOTE The front right hand screw is a hollow screw and shall be provided with an O ring 1 under its head Tighten the screws with a torque of 15 Nm 11 lb ft Tighten diagonally ...

Page 49: ...e the shift shoe 1 with the shift mechanism 3 Loosen and remove the 4 allen head bolts holding the double bearing box 4 Pull out the double bearing box by pulling and turn ing simultaneously Use strap wrench 9999179 to ro tate the double bearing box IMPORTANT Do not damage or lose the shims Disassembly models 290A SP and DP NOTE The illustrations show drives model DP but the working methods are th...

Page 50: ...the vertical shaft Use special tool 884830 and the spline shaft as a counter hold while removing the nut 8 Lift out the upper bearing assembly along with the sliding sleeve and the spring 9 Lift out the upper gear housing from the special tool Disassemble the bearing assembly and shaft by lifting the shaft enough to remove the split locking ring 1 then the thrust washer 2 NOTE Do not scratch the s...

Page 51: ... special tools 884259 with handle 9991801 12 Brace the universal joint in a vice Use soft jaws to protect the universal joint Use special tool 885043 to remove the TX50 torx head screw and the tapered washer discard the screw NOTE Sterndrives model 290A have an Allen head screw instead of a TX50 torx head screw Remove the double bearing box from the universal joint 11b Drives without intgrated bea...

Page 52: ... bearing Use special tool 884263 NOTE The bearing will be damaged if removed only remove if a new bearing will be installed 16 Use a knife puller to remove the roller bearing from the gear if necessary Also use special tool 884266 13 Use special tool 3850608 to remove the locking ring 1 remove the shoulder washer 2 NOTE The seal ring 3 can be removed at a later time 1 2 3 3850608 884938 884266 884...

Page 53: ...ndition the universal joint See chapter Reconditioning the universal joint pages 62 63 Assembly models 290A SP and DP NOTE When assembling the upper gear housing it is very important that the gears are correctly positioned in relation to each other This applies not only to the backlash between the gear teeth but also to the gear teeth contact Correct gear teeth contact spreads the load to which th...

Page 54: ...bearing in a way that a 1 mm 0 0394 approximatively clearance is ob tained Use special tool 884263 NOTE Protect the gear teeth 4 Press down the sealing ring to the shoulder Use special tool 884932 with handle 991801 and special tool 884938 Then install the locking ring with special tool 3850608 884263 9991801 884932 884938 5 Coat the O ring 1 with grease and insert it in its lo cation Push the sho...

Page 55: ...ressing between each interval see under the fol lowing point and rotate the bearings continuously to allow them to set Model 290A has an Allen head screw instead of a TX50 torx head screw 7 Check the pre stressing of the bearings between the tightening intervals and then use a spring type of scale special tool 9985494 Pre stressing new bear ings 10 15 N 2 20 3 30 lbs Prestressing used bearings 7 5...

Page 56: ...g deformed 8b Drives with integrated bearings From models SP A1 DP A1 on Lubricate the bearings with synthetic gear lube API GL 5 Press the bearing onto their respective gears Use special tool 884168 NOTE Protect the gear cup during the compression to avoid that it is being deformed 1 2 9 Always start by adjusting the forward gear If the previously dismantled gears are to be used it is im portant ...

Page 57: ...al value for both B and C is 61 00 mm 2 40 Add this value to the value stamped into the gear to calculate shims for the forward and reverse gears The shim calculations can be seen in the example be low Measurement A 62 05 mm Fixed Dimension 0 05 mm Gear Etching1 62 10 mm C Stamping 61 78 mm Stamped 2 0 32 mm 0 013 The shim thickness for the forward gear is 0 32 mm 0 013 The shim thickness for the ...

Page 58: ... 2 15 Install the washer 2 and the split locking ring 1 and tighten the left hand nut at the opposite end of the vertical shaft Use special tool 3850598 2 1 NOTE When calculating the shim thickness for the forward and reverse gears remember The upper gear housing nominal dimension has two values If the stamped number is 50 or more use the lower nominal value 61 00 mm If the stamped number is 49 or...

Page 59: ...earing box and the gear housing If the backlash is too loose shims must be removed from the double bearing box A shim thickness of 0 10 mm 0 004 is a safe adjustment step 16 a Drives with integrated bearings From models SP A1 and DP A1 on Brace the special tool 884387 plate and ring 885153 tool kit 885152 in a vise and install the gear housing in the tool 16 b Drives without integrated bearings Up...

Page 60: ...h will show a picture of the contact pattern 22 Dismantle the gear set and compare the contact pattern to that of the picture A This picture shows the desired pattern for the drive side of the forward and reverse gear The drive side is the convex side of the gear The dye pattern should be nearly oval in form and be positioned half way up on the gear tooth It should be displaced towards the small e...

Page 61: ...g Feel by hand to make certain 24 If the dye pattern reflects a contact pattern as shown in picture C the shim thickness underneath the drive gear double bearing box must be in creased The drive then moves away from the cent er NOTE If the drive is moved in or out respectively also the gears must be moved in or out in order to maintain the correct backlash Having obtained the correct backlash and ...

Page 62: ...TE Carefully inspect the condition of the brass washer and replace if necessary 5 Place the upper gear wheel with the calculated shims in the gear housing Install the needle bearings 1 along with the spacer ring 2 model 290A only between the bearings 6 In order to obtain the correct axial clearance there are three left hand threaded nuts with shoulders of dif ferent thicknesses 1 Select a nut and ...

Page 63: ...35 Nm 25 8 lb ft 10 Install a sufficient number of shims underneath the cover to obtain a clearance of max 0 1 mm 0 004 between the cover and the gear housing Lo cate the cover and push it lightly into position and measure the clearance all around with a feeler gauge 7 Measure the clearance between the nut and the bearing The axial clearance should be 0 1 0 5 mm 0 00394 0 0197 If it should not be ...

Page 64: ...ealing for the front right hand screw ends up in the recess of the cover provided for it 12 Insert the calculated shims and tighten the cover NOTE The front right hand screw is a hollow screw to be installed with an O ring underneath the head of the screw Tighten the screws with a torque of 15 Nm 11 04 lb ft in diagonal sequence ...

Page 65: ... of pliers or Channel Lock pliers If this is unsuccessful the bear ing can be driven out by using a hammer and a drift punch Once the bearings are removed remove the spider from the yoke 4 Inspect the spider 1 and needle bearings for play in the yokes 2 3 and 4 and possible wear marks in the bearing races 5 If faulty the spider 1 and nee dle bearing caps 5 must be replaced as a complete unit NOTE ...

Page 66: ...cap to keep the needle bearings in place Press the needle bearing cap into the yoke far enough to allow the lock ring to be installed Install the remaining needle bearing caps in the same manner WARNING Be extremely careful when pressing the needle bearing caps into place The needle bearings may come loose and fall to the bottom of the bearing cap DO NOT force the needle bearing caps onto the spid...

Page 67: ...0A there are 3 different types of shift mechanism The first type was installed up to and including serial no PZ 2829528 As from serial number PZ 2829529 the sec ond type where the ball spring and the locking wire were removed was installed There is a somewhat different dismantling and assembly sequence for each type The third type and the shift mechanism for models DP and SP are described on pages...

Page 68: ...f and turn down the end into the cover recess The only func tion of the locking wire is to hold the spring in posi tion while the shift mechanism is being installed in the gear housing 6 Install the spring 1 the shift shoe 2 and the O ring 3 and coat the contact surfaces with sealing compound Volvo Penta part no 1161099 5 or Permatex no 3 Assembly Oil all moving parts prior to the assembly 3 Lubri...

Page 69: ...g the one in the picture The shift mechanism will not function if the sliding shoe is turned the opposite way Now install the shift mechanism in the sterndrive Set the shift mechanism in neutral and remove all adjustment pads 3 and tighten the screw Now the vertical shaft in the upper gear housing cannot be turned Insert a shim at the time on the screw until it is possible to turn the shaft Models...

Page 70: ...mbly Oil all moving parts prior to assembly 11 Install the spring 1 the sliding shoe 2 and the O ring 3 and coat the contact surfaces with sealing compound Volvo Penta part no 1161099 5 or Permatex no 3 12 Install the shift mechanism in the gear housing in a way that the screw 1 is displaced towards star board NOTE Make sure that the sliding shoe 2 is turned to a position corresponding the one in ...

Page 71: ...ift mechanism in the sterndrive 14 Remove all adjustment shims 1 and tighten the screws Now it is not possible to turn the vertical shaft in the upper gear housing Insert an adjustment shim at the time on the screw until the shaft can be turned again without any sort of resistance Models 290 and 290A Add one more shim to the screw 1 When the adjustment is done coat the shims and the screw with sea...

Page 72: ...he eccen tric piston for scoring distortion or damage that may cause it to leak or bind in the housing 1 20 Using a screwdriver pry out the eccentric piston seal Clean all surfaces and check for damage that may cause leaks Replace parts as necessary 21 Install a new eccentric piston seal with the steel edge facing inward as shown Use special tool 884793 Assembly models 280 285 285A 290 and 290A Oi...

Page 73: ...ion 25 Set the shift mechanism in a position between forward and neutral or between reverse and neutral The pin 1 shall rest on one of the cams Install the shift mechanism in the sterndrive 1 2 3 1 2 3 22 Install the eccentric piston 1 in the housing Do not damage the seal Push in the locating pin 2 Align the hole with the housing Lock it in place with a new spring pin 3 23 Install a new O ring 3 ...

Page 74: ... screw 27 Install a new eccentric piston seal with the steel edge facing inward as shown Use special tool 884793 Assembly models SP and DP Oil all moving parts prior to assembly 1 2 3 29 Install a new O ring 3 then insert the spring 2 and shift shoe 1 Coat the contact surface with Vol vo Penta part no 1141570 0 sealant 1 2 3 28 Install the eccentric piston 1 in the housing Do not damage the seal P...

Page 75: ...w 1 and install finger tight while rotat ing the propeller shaft by hand If propeller shaft binds repeat this step adding one shim at a time un til no resistance is felt through 360 of rotation NOTE Do not attempt to rotate the propeller shaft with any leverage devices e g propellers or pliers This will damage the sliding sleeve and or the shift shoe After the proper amount of shims have been esta...

Page 76: ... and the gasket 2 Dismantle the yoke by driving out the steering spin dle Use special tools 884311 and 9991801 Then re move the retaining pawl from the yoke 3 Remove the plastic washers 1 and the wear wash er 2 4 Press out the sealing rings and the needle bearing Use special tool 884259 and 9991801 NOTE There is a sealing ring on each side of the needle bearing 884311 9991801 884259 9991801 ...

Page 77: ... 884143 Also replace the O rings 1 One at each end of the tube 8 The retaining pawl is dismantled when necessary as follows Remove the shaft journals 48 Remove the spring 57 the spring 49 and the springs 58 NOTE Hold the spring shaft 50 Remove the nuts 55 and the spring catches 52 and 54 and the spacer washers 44 and the retaining pawl 42 Lift out the bearing 43 and the shaft 53 and the push rod 4...

Page 78: ...o make the spring catches movable without adding a play Then install the locking yoke 47 and the shaft journals 48 along with the spring 57 and the washer 51 in the bearing 43 Install the spring shaft 50 with the as sistance of the springs 58 and install the spring 49 between the bearing 43 and the stop shaft 56 10 Paint the retaining pawl with a thin layer of touch up paint Painting is hard to do...

Page 79: ... pawl in its location in the inter mediate housing NOTE Insert the wear washer 1 between the lower attachment of the yoke and the intermediate housing and the two plastic washers 2 with one on each side of the bearing Then press in the steering spin dle until the collar bottoms Be very careful during the installation of the steering spindle in order to avoid damaging the lower sealing ring 15 Inst...

Page 80: ...mediate housing model 290 and 290A 1 Remove the 2 screws holding the hose connection Remove the hose connection and the gasket 2 Remove the yoke by driving out the steering spin dle Use special tools 884311 and 9991801 Lift up the attachment device of the trim cylinders and remove the retaining pawl the two wear washers the plastic washer and the guide washer from the steering yoke 9991801 884311 ...

Page 81: ...bearing 4 Press out the bushing Use special tools 884259 and 9991801 5 Should the shift yoke be in need of being replaced remove the cotter pin 1 Then pull out the shaft 2 and remove the shift yoke 3 6 Remove the bearing race of the axial bearing Use special tools 884140 and 884143 Also replace the O rings 1 One in each end of the oil tube 9991801 884259 9991801 884259 ...

Page 82: ...nd the spring catch 37 the spacer sleeve 36 on the shaft 35 and the bearing 32 Install the second nut 38 NOTE Tighten the nuts 38 completely Then ease off a 1 8 turn to allow the spring catches to move without adding a play Then install the locking yoke 41 and the shaft journals 42 with the spring 43 and the washer 46 in the bearing 32 Install the spring shaft 45 in its location with the assistanc...

Page 83: ...3 Place the yoke and the wear washer 1 on the in termediate housing and push in the steering spindle 2 as far as to hold the wear washer NOTE Be careful not to damage the lower sealing rings 14 Insert the retaining pawl into the intermediate housing Then insert the plastic washer 1 and the guide washer 2 between the retaining pawl and the intermediate housing Then push in the steering spin dle as ...

Page 84: ...mpound Volvo Penta part no 1161099 5 or Permatex no 3 17 If the trim cylinder attachment is in need of repair or in need of being replaced remove the 2 collar screws Use a socket wrench 17 mm as a counter hold Then install the new cylinder attachment NOTE Use the same screws washers and nuts un less they are damaged 18 Install the shift yoke 3 and push in the shaft 2 and lock it with the cotter pi...

Page 85: ...hose connection and the gasket 2 Remove the hook up fork by driving out the steering spindle Use special tools 884311 and 9991801 3 Press out the lower steering spindle bushing Use special tools 884259 and 9991801 4 Press out the upper steering spindle bushing using special tool 884259 and 9991801 9991801 884311 9991801 884259 9991801 884259 ...

Page 86: ...g 6 Remove the bearing race of the axial bearing Use special tool 884140 and 884143 Also replace the O rings 1 One on each side of the oil tube 7 Grease the lower hook up fork bushing with Volvo Penta part np 828250 1 water resistant grease Using special tool 884259 and 9991801 press in the bush ing 8 Press the bushing into the hook up fork Use spe cial tools 884259 with handle 9991801 9991801 884...

Page 87: ...ing exhaust port 2 stopping short of the upper hook up fork bushing 11 Insert the plastic wear washer 1 between the in termediate housing and the hook up fork Push the steering spindle in until the collar bottoms 12 Install the O ring and the hose connection on the yoke Use a small amount of Volvo Penta part no 828250 1 water resistant grease to hold the O ring in place while installing the hose c...

Page 88: ...85 Repair instructions 13 Install the shift yoke 3 Align the shift yoke with the shaft hole in the intermediate housing Push the shaft 2 through and lock it with a new cotter pin 1 ...

Page 89: ...e the oil strainer 1 and the O rings 2 and 3 only models 280 285 and 290 4 Remove the 2 screws holding the propeller bearing housing Remove the propeller shaft and the propel ler bearing housing Use special tool 884161 Re move the special tool once the propeller bearing housing is free and pull out the bearing housing by hand 3 Use special tool 884830 and install the lower gear upside down 1 2 3 8...

Page 90: ...ss off the gear wheel and the bearing from the propeller shaft simultaneously Use special tool 884168 8 Remove the locking ring 1 and the oil deflector 2 from the gear wheel NOTE In order not to damage the oil deflector dur ing the dismantling apply the bending tool close to the 2 carrier pins 3 This is valid for sterndrives of earlier manufacture On sterndrives of later manu facture the carrier p...

Page 91: ...a Models 280 and 290 of earlier manufacture and model SP Fold down the tab of the locking washer 1 and remove the round nut 2 Remove the locking washer and the spacer ring 3 11b Models 280 290 of later manufacture Lift the gear housing off the special tool and place it back in the work stand Remove the nylock nut with a hook spanner wrench 12 Use special tools 884267 and 884830 to remove the pinio...

Page 92: ...ff the lower gear housing from the vertical drive shaft NOTE Take care of the shims 1 15 Press knock off the outer ring of the needle bear ing Use special tools 884381 and 884143 Insert the tool from underneath and the shaft from above 16 Press off the ball and roller bearings from the ver tical shaft against the frame of the press NOTE There are spacer pads between the bearings 1 2 3 1 884381 884...

Page 93: ...rts if necessary NOTE The gear wheels are sold in matched pairs in order to obtain the correct contact pattern Assembly Oil all moving parts and the screws prior to as sembly 1 Fill up with grease between the two sealing rings 1 and press them home in the propeller bearing housing Use special tools 884283 and 9991801 NOTE Turn the sealing rings correctly They are to seal against the oil in the gea...

Page 94: ... the gear housing The vertical shaft 4 Press on the ball bearing on the vertical shaft Use special tool 884266 NOTE Install the ball bearing according to figure in a way that the balls 1 become visible 5 Install the spacer pad 1 on the ball bearing and press on the roller bearing Use special tool 884266 6a Models 280 and 290 of earlier manufacture and model SP Install the spacer ring 1 the locking...

Page 95: ... washer 2 for the needle bearing 3 into the gear housing 8 Install the vertical shaft with a 0 35 mm 0 14 thick shims package 1 consisting of a paper shim 0 25 mm 0 01 between two metal shims 0 05 mm 0 002 each 9 Install the washer and the nut Tighten the nut with a torque of 160 Nm 118 lbf ft Use special tool 884830 on the splined end as a counter hold NOTE Don t lock just yet 1 2 3 1 884830 ...

Page 96: ...ace and the tool to prevent the vertical shaft from moving axially Tighten the spanner tool with two screws and nuts The propeller shaft 12 Install the oil deflector 1 and the locking ring 2 on the gear wheel 3 NOTE Make sure that the two holes on the oil deflec tor coincide with the carrier pins on sterndrives of ear lier manufacture On sterndrives of later manufacture a load pin acts as carrier ...

Page 97: ...e balls is turned facing the propeller 16 Install the locking washer 1 and the round nut 2 Tighten the nut and lock it with the locking washer 3 Shimming Method 1 1 The lower gear housing is stamped with a F measurement center vertical shaft contact sur face of the propeller bearing box the propeller bear ing box is stamped with a G measurement shoul der of the propeller bearing contact surface of...

Page 98: ...ickness can be seen in the following example Measurement F 4 97 0 195 stamped Measurement G 0 98 0 039 stamped 5 95 0 234 5 95 Gear wheel 5 85 0 230 fixed Gear wheel marking 0 04 0 002 etched 5 89 5 89 Calculated sum always positive 0 06 0 002 As per this example a 0 05 mm 0 002 shim is in serted between the propeller bearing box and the propeller thrust bearing Carry on according to points 4 12 b...

Page 99: ...o be correct adjust as follows If the method 1 has been used If the backlash is too small increase the shim thickness underneath the ball bearing 1 and if the backlash is too big de crease the shim thickness If method 2 has been used If the backlash is too small decrease the shim thickness in the propeller bearing housing 2 and if the backlash is too big in crease the shim thickness 8 Remove the s...

Page 100: ... the picture A which is correct The contact pattern should be positioned in the middle of the tooth but displaced to wards the small end 11 Should the contact pattern correspond to that of picture B reduce the shim thickness for the vertical shaft and the propeller shaft 12 Should the contact pattern correspond to that of picture C increase the shim thickness for the verti cal shaft and the propel...

Page 101: ...on nut with a torque of 160 Nm 118 lb ft Then lock the nut with the locking washer 1 Use special tool 884830 applied at the splines shaft end as a counter hold 3 Install the O rings 1 in the propeller bearing hous ing Coat the contact surfaces and the screws with sealing compound Volvo Penta part no 1161099 5 or Permatex no 3 Install the propeller bearing housing in the gear housing and tighten th...

Page 102: ...holding the lower unit on the intermediate housing Two bolts are inside the shift mechanism cover 4 Install the suspension fixture 885192 in stand 99922520 and brace the lower unit in the stand 5a Models 280 DP and 290 DP Take care of the spline sleeve 1 the oil strainer 5 and the ring 2 5b Model DP Remove the spline sleeve 1 and the O rings 2 and 3 Remove the spacer sleeve along with the O ring 4...

Page 103: ...O rings 1 from the propeller shaft housing Discard the O rings 10 Install special tool 885197 on the inner propeller shaft 11 Install special tool 884802 over the inner propeller shaft Add the washer and nut from tool 885197 The slot in the end of the tool should face the pinion gear Tighten the nut until the shaft is extracted from the forward gear Use a 30 mm wrench 12 Brace special tool 884830 ...

Page 104: ...al tool 884830 and turn counter clock wise until the shaft can be lifted out of the lower unit gear housing Remove the tool from the shaft Re move the shims from under the vertical shaft bearing NOTE Be sure not to damage the shims Save them for use later in the assembly process 14b NOTE Sterndrives model 280 and 290 of earlier manufacture have a lock washer 1 and a round nut 2 instead of a Nylock...

Page 105: ...shims Outer propeller shaft 20 Insert the shaft in special tool 884831 Install pull er halves between the shaft and the special tool In stall special tool 884789 on the shaft to protect the shaft during pressing operations Press off the bearing race WARNING Do not use a knife puller or other similar tool to remove this bearing race Such tools may scratch the sealing surfaces of the shaft 1 and res...

Page 106: ... gear 23 Remove the inner needle bearing and seals using special tools 884803 and 884143 Install special tool 884789 to protect the propeller shaft threads NOTE If you only want to replace the seals it is still easier to remove the seals along with the bearings Propeller shaft bearing box 24 Remove the O rings from the propeller shaft bear ing housing and discard Using special tool 884797 to press...

Page 107: ...e puller to press off the front roller bear ing from the gear Vertical shaft 27 Use a knife puller to remove the bearings one by one or together IMPORTANT Use spline socket 3850598 to protect the splines when pressing off the bearings 29 Remove the ball bearings Use a knife puller 884796 9991801 28 NOTE There is a spacer pad 1 located between the roller bearing and the ball bearing This spacer pad...

Page 108: ... 85 NOTE When calculating the shim thickness for the lower unit gears remember The lower unit gear housing nominal dimension has two values If the stamped number is 50 or more use the lower nominal value 60 00 mm If the stamped number is 49 or less use the higher nominal value 61 00 mm Example Stamping is 50 or more G stamping 85 00 85 mm Use Nominal Dimension 60 00 mm G measurement 60 85 mm Stamp...

Page 109: ...ard gear length 60 25 mm This sum should be subtracted from the G stamping resulting in a shim thickness for the front bearing G measurement 60 85 mm Total forward gear length 60 25 mm Shim Thickness 00 60 mm 4 Lubricate the bearing position before assembly Place the calculated shim thickness in the gear hous ing and install the outer bearing race marked 30209 with special tool 884795 NOTE The pla...

Page 110: ...ecial tool 884792 in combination with 884241 Turn the bearing to allow the tool 884792 to press against the text on the bearing Tighten the screw until the bearing bottoms 8 Press a new inner bearing race onto the vertical shaft Use special tool 884793 9 Press a new ball bearing onto the vertical shaft special tool 884266 NOTE Install the bearing so that the thick part of the inner race faces up 1...

Page 111: ... washer 2 and the round nut 3 on the vertical shaft NOTE Install the nut with the even side facing up wards Tighten the nut but don t lock it with the wash er Use a hook spanner wrench 11b Sterndrives model 280 and 290 of later manu facture and sterndrives model DP Install the thick spacer ring and tighten the plastic in sert locknut Use a hook spanner wrench 13 Find the marking on the pinion gear...

Page 112: ...ve at the shim thickness Subtract Vertical Shaft Calculated 277 70 mm H Measurement 277 37 mm Calculated Shims 0 33 mm 15 Place the propeller shaft with gear installed in the gear housing 16 Place the calculated shim thickness 1 in the gear housing In this case it is 0 33 mm With one hand hold the pinion gear and the original pinion gear nut in the gear together in the housing 17 Center the pinion...

Page 113: ...g the amount of variation from nominal that the housing is machined When the F stamping is between 90 and 99 add 79 00 mm to the figure If the F stamping is between 00 and 10 add 80 00 mm to the figure In this case the F stamping is 91 Add 0 91 to the nominal figure of 79 00 The sum for the F measurement is 79 91 20 Find the stamping C on the bearing box In this case C 25 Again the stamping is in ...

Page 114: ...s marked K354X Installing the bearings in the wrong location will cause incorrect lower unit gear contact patterns incorrect bearing preload and shorten gear life 23 Add the gear measurement to the bearing nominal dimension Add Gear measurement 39 60 mm Nominal bearing height 20 75 mm Total aft gear dimension 60 35 mm Now subtract the total aft gear dimension from the bearing box location Subtract...

Page 115: ...ing box over Use special tool 884797 install the needle bearing in the bearing box Make sure the bearing marking is facing the tool Shimming the intermediate bearing 26 Start by adding the F measurement and G measurement Add G measurement 60 85 mm F measurement 79 91 mm 140 76 mm Now subtract the C measurement of the propeller bearing box Subtract F and G combined 140 76 mm C measurement 19 25 mm ...

Page 116: ...nvex side of the aft gear Place the calculated shims for the intermediate bearing and the intermediate bearing on the inner pro peller shaft Install special tool 885197 onto the threads until the tool bottoms 33 Install special tool 884798 on the propeller shaft with the washer and nut Using a 30 mm wrench tight en the nut until the intermediate bearing bottoms Use special tool 884830 or 3850598 a...

Page 117: ... nuts finger tight to prevent axial movement but not enough to preload the vertical shaft 884348 A 37 Using a depth gauge measure B in special tool 884348 Subtract measurement A from measure ment B B A positive result clearance dimension B A negative result preload Tolerances Max allowed clearance dimension 0 05 mm 0 002 Max allowed preload 0 02 mm 0 0008 A clearance dimension of 0 02 mm 0 0008 sh...

Page 118: ...s by hand to check the backlash The clearance at the wing should be 0 08 0 17mm 0 003 0 007 which results in a clearance of 0 15 0 30mm 0 006 0 013 at the gear Propeller Cone 42 If the rear propeller is locked with a propeller cone measuring the gear backlash must be done the same way as when measuring using the propeller nut The only difference is that the measuring must be done 8 mm 0 315 in fro...

Page 119: ...ed towards the big end with a slight displacement toward the root of the tooth A 1 2 4 1 3 44 If it is necessary to increase the backlash without changing the contact pattern shims must be removed from the front and rear gears 1 and shims must be added under the vertical shaft 2 to compensate the play Add the shim thickness corresponding to that removed from gears 1 to the bearing 3 to maintain pr...

Page 120: ...all end reduce the shim thickness for under the front and rear roller bearing 1 figure under point 44 To maintain proper bearing preload increase the shim thickness correspondingly under the intermediate bearing 3 To maintain the correct backlash decrease the shim thickness under the vertical shaft ball bearing 2 Final assembly 1 After the correct preload backlash and contact pattern have been obt...

Page 121: ...ess until it bottoms 5 Grease the seal rings and install in the bearing box with the springs facing away from each other Use special tool 884801 Press until it bottoms 6 Insert the protective ring 884976 into the outer propeller shaft seals so that the seal lips are protected during installation 7 Carefully insert the outer propeller shaft in the gear housing Remove the seal protector 8 Install se...

Page 122: ...alled and tightened Clean off any excess sealing compound 12 Install the zinc ring on the lower gear housing Check to make sure that the contact surfaces are clean and there is a good electrical contact An ohmmeter may be used to ensure there is little or no resistance between the zinc ring and the lower unit housing For more detailed information about Electrochemical Corrosion what causes it and ...

Page 123: ...5 mm 0 002 Max allowed preload 0 02 mm 0 0008 For calculation of shims see point 37 on page 114 3 Press the outer race of the vertical shaft bearing with the calculated shims into the intermediate hous ing Use special tool 884168 4 Insert the oil strainer 5 into the lower gear hous ing Check that the spacer sleeve 4 is provided with an O ring Use new O rings 3 and 4 Install the spline sleeve 1 on ...

Page 124: ...wrench to 38 Nm 28 lb ft Use special tool 885008 Tighten the 3 smaller screws to 15 Nm 11 lb ft 280 drives Earlier 280 drives do not have washers while later ver sions do Both versions of the 280 drive shall always have washers fitted to all bolts between the lower and intermediate housing when overhauling Tightening torque see above 290 drives All production 290 drives have washers fitted Tighten...

Page 125: ...hickness A figure under point 1 from the intermediate housing measurement to find the bearing clearance Add enough shims to take up the clearance plus 0 06 mm shim to preload the upper gear head bearing Apply a light coating of Volvo Penta part no 1141570 sealant to the mating surfaces of the intermediate housing and the upper gear head Install the upper gear head on the intermediate housing with ...

Page 126: ...s applies to all drives Apply some grease to the Allen bolt and stud threads and to the contact faces of the nuts and washers Tighten the screws and nuts in diagonal sequence and evenly all around and with a torque of 38 Nm 28 lb ft Use tool 885008 and 885009 7 Install the shift linkage rod washer and cotter pin WARNING Always use a new cotter pin Never reuse a cotter pin that has been removed 1 5...

Page 127: ...oss is indicated increase the pres sure to 110 124 kPa Again use a soapy water solu tion or dip the drive to find the leakage point if the drive looses pressure Do the necessary repairs and then repeat the test The drive must hold its pressure before the vacuum test is done and must not loose more than 7 kPa in 3 minutes c Connect a vacuum tester 3858578 to the drain hole and evacuate the drive to...

Page 128: ...ling water hose 3 between the transom shield and the sterndrive NOTE The cooling water hose is marked engine at the end to be connected to the transom shield Check to make sure that the hose clamps are well tightened to avoid water leaking into the boat Use the flexible screwdriver 884573 to tighten the clamps 2 Check to make sure that the hole in the suspension yoke for the push rod is chamfered ...

Page 129: ...sponding female splines of the joint more easily NOTE Be careful during the assembly not to damage either splines thus making the mating more difficult Install the two plastic bushings 2 figure under point 1 in the holes of the suspension yoke Grease the shaft journals 4 with grease or Molycote Insert the sterndrive suspension yoke into the tran som shield and align it to allow the shaft journals ...

Page 130: ...y Then push the sterndrive forwards against the adjust ing pin and check that the upper end of the push rod 3 does not touch the thrust plate of the lift device The lifting device 1 when tilting will disengage the retaining pawl The retaining in the adjusting pin of the retaining pawl is checked by first pulling the sterndrive backwards and then in the two outer positions Then check that the elect...

Page 131: ...i nating the need to remove the shaft from the drive unit as follows 1 Install drill jigg on propeller shaft 2 Drill a 6 5 mm 0 255 hole to a depth of 20 mm 0 787 Use cutting oil to cool shaft Clean thor ougly 3 Usa a 5 16 18 UNC taps to thread shaft Clean thorougly 4 Install propeller plastic washer cone and center bolt Torque cone 110 Nm 81 ft lb bolt 22 Nm 16 ft lb Propeller installation On pro...

Page 132: ...ler rotation The upper gear is designed in a way it does not have to be changed if you want to change the propeller ro tation With the standard rotation left hand rotating propeller the lower gear wheel is operating as forward gear and the shift rod is located in accordance with A on the picture With a right hand rotating propeller the up per gear wheel is operating as forward gear and the shift r...

Page 133: ...al motor has to cool down approx an hour before the tilting device can be operated again 1b Burnt electrical motor If the tilt motor is operated too long after the stern drive has reached its top position the motor can burn To avoid this an overload circuit breaker can be installed on the transom NOTE On sterndrives of later manufacture this over load circuit breaker is standard equipment Install ...

Page 134: ...ace parts if necessary 7 Assemble the tilting device in the reversed order Grease the parts in an universal type of grease at the assembly Also fill the upper housing with grease Connect the minus earth wire 2 and 3 as indicat ed in the picture and the wire harness 1 to the con trol switch Checking after reconditioning Check after the installation that the tilt and retaining pawl mechanism functio...

Page 135: ...lamp and install the universal joint bellows Locate the tightening screw at 3 o clock 3 Remove the locking screw and remove the sus pension pin Grease the suspension pins with Volvo Penta low temperature grease 1161417 9 and install in the transom shield flush with the interior face to the transom shield Grease the locking bolt with Volvo Penta low temperature grease 1161417 9 Put the locking bolt...

Page 136: ... in its groove in the cable cover Tighten the locking plate with the 2 stainless steel screws Key width 11 mm 7 Install the plastic bushings 1 in the holes 2 of the suspension yoke 8 Push the sterndrive forwards against the engine primary shaft and turn the universal joint simultane ously to better allow the primary shaft splines to en ter the universal joint A small guide in the joint facili tate...

Page 137: ...e a screwdriver to turn the dowels so that the locking grooves coincide with the locking screw holes in the ears of the transom shield Tighten the locking screws Prior to the tightening of the screws grease them with low temperature grease Volvo Penta part no 1141644 3 NOTE Don t forget the washer under the screw heads Tighten torque 24 Nm 17 lb ft Remove the installation tool 12 Push the rubber b...

Page 138: ...other bellows 14 Hang on the hose clamp for the exhaust bellows and push it onto the neck of the sterndrive Turn the hose clamp into the position indicated by the picture See also point 15 15 Check to make sure that all bellows and hoses have been installed correctly and well tightened Tilt the sterndrive and turn it fully both ways and check simultaneously that the tightening screws of the bellow...

Page 139: ... 19 Before connecting the shift cable be sure that if the remote control moves forward the shift cable ex tends from the cable housing i e cable pushes for forward gear pulls for reverse gear Set the stern drive shift lever to horozontal making shure that it is in the neutral detent position Set the remote control shift lever to neutral Push the shift cable in as far as possible Using a fiber tip ...

Page 140: ... in Neutral and check that the rod 6 has a position that it will touch the yoke of the retaining pawl at A However with out pressing against it Adjust if necessary the yoke 11 If a second adjustment is made also point a has to be ad justed once again Oil filling 2 Tilt the sterndrive to the full up position Remove the fill plug 1 and fill with approx 2 2 liters of GL 5 synthetic gear oil See Techi...

Page 141: ...e 1 7 Install and tighten the center bolt 6 NOTE Sterndrive model 290B ratio 1 61 1 is differ ent from sterndrive model 290D ratio 2 15 1 The dif ference consists of propellers with long and short hub respectively See the picture NOTE Short hub propellers folding washer and cone will be replaced by long hub propellers plastic washer cone center bolt When installing long hub propellers on older ste...

Page 142: ...rom A to B Check to make sure that the adjustment of the retaining pawl and the shift mechanism is still intact Install the shift mecha nism cover NOTE There is no need to alter the direction of rota tion on the Duoprop sterndrive in a twin installation On the propeller hub there is a L for left hand rotating and a R for right hand rotating propeller Also the size of the propeller is stamped into ...

Page 143: ... RH Right hand NOTE The figures show the boat drive from above Tightening torque 14 17 Nm 10 12 lbf ft Twin engine installation In a twin installation the Toe out angle between the sterndrives must be adjusted until an operation free from cavitation has been obtained Increase the an gle between the sterndrives on a boat with a deeper V hull Adjust the sterndrives in accordance with the picture If ...

Page 144: ...opellers shall only be used with petrol gasoline engines Duoprop later model Check which speed range the boat in question oper ates in and select the correct propeller Refer to pro peller recommendations NOTE The propellers are supplied in pairs and must not be mixed Use special tool 885127 Install the propellers as follows grease the propeller shaft and fit the fishing line protection 1 and the p...

Page 145: ...ny oil which will leak when the hydraulic lines are disconnected Transom shield Trim cylinders later models B C D A 3 Remove the plastic plug with a 5 mm Allen head key 4 Remove the 2 hoses A from the starboard cylin der If only the port cylinder is to be replaced remove the pipe connections on that cylinder B WARNING Be sure to catch any oil which will leak when the hydraulic lines are disconnect...

Page 146: ...he dowel pin will then be pushed out and the trim cylinder can be removed 9 If the dowel pin will not come out by using a grease gun special tool 884978 should be used as follows Remove the grease fitting Fill the tool with grease Screw the tool into the transom shield and carefully tighten Unscrew the locking trim cylinder pin locking bolt 1 approx 10 mm Hit the tool piston 2 with a hammer so tha...

Page 147: ...12 Remove the grease fitting that was used to remove the attachment pin Grease and install the trim cylinder dowel pin Install the new trim cylinder Remove the attachment bolt from the end of the pin and lock the pin in position with the bolt IMPORTANT The transom must have cutouts called for on the transom template to allow suffi cient clearance for the pins to be removed If the cutouts are not m...

Page 148: ...gs are attached finger tight before torquing any of the fittings Final tightening of any of the fittings before all fittings are started could cause cross threaded fittings and damage the cylinder 15a Port cylinder Remove the block off plugs from the old cylinder and install in the same holes of the new cylinder Install the ground strap insert C attach the ground strap to the insert WARNING Be sur...

Page 149: ...and to make sure that the system is properly filled up The oil level should be level with the oil filler hole Use the same oil quality as for the engine or ATF oil See below Trim pump earlier model 17 Oil level hydraulic pump power trim Trim in the drive as far as possible Check that the oil level is between the max and min marks on the reservoir Top up if necessary with ATF oil NOTE Early product...

Page 150: ...k they must be re placed as a unit WARNING The bolted joints steering helmet steering fork A shall not be dismounted Removal 19 Remove the sterndrive according to procedure elsewhere in this book 20 Disconnect the power steering A if equipped Disconnect and remove the trim sending unit 21 Loosen the tiller arm set screw using a 5 32 allen wrench 22 Gently pry the steering fork down from the transo...

Page 151: ...splines on the steering fork with the square in the tiller arm and install into the transom shield 25 Make sure the square the splines on the steering fork and the tiller arm are aligned 26 Using a rubber mallet tap on the steering fork into position 27 Lock the setscrew with a 5 32 in allen wrench ...

Page 152: ...149 Transom shield 28 Install a new seal 9 and O ring 7 on the gear wheel Install the trim sending unit gear wheel and gear rack See chapter Trim System ...

Page 153: ...h on the sending unit housing 3 Install the sending unit housing into the steering shaft on the transom shield Rotate the sending unit slightly to align the drive coupling with the gear wheel NOTE Do not force the sending unit into the hole This may damage the sending unit and or the gear wheel Install the trim sender bracket and hold down screw Finger tight only do not tighten until all adjustmen...

Page 154: ...m angle settings are as fol lows 6 Tighten the trim sender bracket hold down screw Be sure the sending unit does not move when the bracket is tightened Changing the trim system gear rack 1 Remove the damaged gear rack by removing the screw 2 Bend the gear rack up slightly to clear the nut and pull it out from the steering helmet Transom angle Instrument indication 10 2 11 3 12 4 13 5 14 6 15 7 ...

Page 155: ...eering hel met Push the nut 1 through the helmet and into the gear rack 6 Install the screw and carefully tighten NOTE It is recommended that a new screw be used whenever the gear rack is removed WARNING Do not overtighten the screw Use extreme caution to prevent stripping the threads from the screw 7 Lower the sterndrive to its bottom position Ensure the sterndrive is at its lowest position place...

Page 156: ...l 1 Remove the sterndrive according to the section in stallation and removal 2 Pull the steering helmet aft far enough to clear the gear wheel Turn the gear wheel so that the digital trim instrument indicates 4 3 Pull the gear wheel straight down There will be some resistance because of the retaining pawl in the bushing Note the position of the drive end of the shaft when removing it This will eas...

Page 157: ...ack on the steering hel met 5 Position the gear wheel as shown 6 Push the steering helmet into position with the marked tooth of the gear wheel engaging the first notch of the gear rack Push the steering helmet as far forward as possible Install the sterndrive accord ing to the installation section earlier in this chapter Check the trim adjustment according to adjusting the trim instrument section...

Page 158: ...pter and basic pump assembly1 6 Filter 7 Reservoir assembly 8 Reservoir seal 9 Reservoir cap 10 Reservoir 11 12 13 Screw spacer O ring assy 14 Thermal relief valve1 15 High pressure relief valve1 16 Low pressure relief valve1 A B C Original factory fitted valve assy 1 Non serviceable part Replace as complete unit Note Do not disassemble the valve or adapter as semblies as this will disturb the fac...

Page 159: ...lt the oil pump mount ing bracket Hold the pump upright to avoid oil spill age Drain the oil from the pump WARNING Always exercise great cleanliness when working with hydraulic systems Do not al low dirt or other impurities to enter the system Use lint free rags when cleaning parts Always fill with clean oil of the recommended quality Replacing filters Removing the oil reservoir Remove the center ...

Page 160: ...or Install the motor on the adapter assembly ensuring the drive shaft engages the coupling Tighten the two studs The adapter and pump assembly contain no servicea ble parts and are replaced as a complete unit Remove the oil reservoir motor and coupling Remove the valve assemblies using a 7 16 wrench The original factory fitted valves cannot be installed in a new adapter pump assembly Install new r...

Page 161: ...ure connection Connect the wiring harness the ground and posi tive cables Fill the reservoir with recommended oil to the proper level between MIN and MAX marks Venting system Reconnect main battery switch and operate the trim pump system is self bleeding Re check the oil level and add if necessary Test Once the system has been vented operate the trim pump for proper operation Check pump and hose c...

Page 162: ...ing B until the instrument shows the correct figure according to the table Then retighten the fixing bracket for the sender and re move the load from the drive 2 Trim down the drive to its bottom position NOTE Push the switch upwards Checking the trim figure 1 Turn the ignition key to the ignition position the lights are on 3 To ensure that the drive rests against the adjusting rod it should be lo...

Page 163: ...n the contact surfaces of the housing carefully Check the O ring and replace it if necessary Press in the outer bearing race of the axial bearing in the extension See under Shimming the intermedi ate housing and the lower gear housing NOTE Measure the measurement B on the exten sion The 4 extension Coat the contact surface with a sealant Volvo Penta part no 1141570 0 Use the 3 new O rings and the ...

Page 164: ...agonal se quence Use the existing washers H on the nuts On the 4 extension the screws K and the washers L are used instead of nuts and washers Tightening torques see the picture Install the cover over the shift mechanism If the paint has been damaged use touch up paint to repair See under Accessories Aquamatic Fill up with lubrication oil Regarding oil quantity and oil quality see chapter Technica...

Page 165: ... at the steering spindle and around the up per and lower bearing positions of the vertical shaft 5 The lower unit housing on the cavitation plate and the exhaust channel except around the bearing positions The lower fin provided no more that 2 3 of it is missing measured vertically The water intake channel at the front of the housing how ever it is important to maintain the channel pro file The co...

Page 166: ...tal surfaces lightly using a 120 grade paper and a finer grade for painted surfaces Wash off using thinners or similar Any pores in the surface should be filled and sanded down Paint using Volvo Penta original primer and topcoat Let the paint dry The drive should be painted with Volvo Penta anti fouling to prevent fouling Apply according to the instructions on the packaging IMPORTANT The sacrifici...

Page 167: ...d to engine 12 Connector 13 Fuse 20 Amps USA model Diesel Gas 75 75 Up Down GN Y 1 3 SB 1 3 SB 1 3 GN 1 5 BL 1 5 No Com No Y 1 5 GN Y 1 5 R 1 5 R 1 5 GN Y 1 5 BL 1 5 BR 1 5 GN 1 3 GN Y 1 5 SB 1 5 BL 1 5 BR 1 5 R 1 5 R 1 5 BL 1 5 BR 1 5 BL 1 5 BR 1 5 Y 1 5 GN Y 1 5 SB 1 5 Up Down Y 1 5 SB 2 5 R 2 5 SB 2 5 SB 2 5 SB 2 5 BR 2 5 SB 1 5 BR 1 5 SB 2 5 R 2 5 R 2 5 R 6 Cable colour codes R red SB black GN...

Page 168: ...Relay 9 Bypass switch 10 Trim limit switch Cable colour codes R red SB black GN green BL blue W white GN R green red GN Y green yellow IV SB ivory black PU purple Cable area 1 5 mm2 Ground OR W IV SB PU GN R GN Y SB PU Power lead SB SB GN GN R R R Down Up Attach to flywheel housing To engine fuse battery side Battery BL ...

Page 169: ...W black white BL R blue red PU purple BL W blue white Cable area 1 5 mm2 1 Oil pump 2 Fuse 55 amps 3 Trim sender 4 Trim indicator 5 Switch 6 Switch relay position Beach 7 Connection instrument panel 8 Instrument lighting 9 Throttle hook up optional 10 Fuse 5 amps 3 Low pressure Down Up 1 Up 2 Positive 3 Down 4 Override button 5 9 2 4 6 7 8 1 10 High pressure ...

Page 170: ...ay position Beach 7 Connection instrument panel 8 Instrument lighting 9 Throttle hook up optional 10 Relays the arrows in the electric wiring diagram refer to the trimming function up down Cable colour codes R red SB black GN green BL blue W white R W red white GN W green white SB W black white BL R blue red PU purple BL W blue white Cable area 1 5 mm2 ...

Page 171: ...ering angle max 30 Overall gear ratio Model 280 280 B1 290 1 61 1 Model 280 280 C1 290 1 89 1 Model 280 280 D1 290 2 15 1 Model 280T 1 61 1 Model 280PT 1 61 1 1 89 1 Model 285 285A 1 61 1 Model 290A 1 61 1 Model 290A 2 15 1 Weight Model 280 52 kg 114 6 lb Model 290 54 kg 119 lb Gear backlash Upper gear measured directly on the gear wheels ratio 1 61 1 0 15 0 25 mm 0 006 0 010 ratios 1 89 1 and 2 1...

Page 172: ...ntermediate housing upper gear housing 38 28 Steering helmet attachment bolt Earlier model 50 60 36 44 Steering helmet attachment bolt Later model 35 25 Pre stressing Input gear in double bearing box 280 290 5 10 N 1 102 2 205 lb Input gear in double bearing box run in gears 280 290 2 5 5 N 0 55 1 102 lb Input gear in double bearing box 290A 10 15 N 2 20 3 30 lb Input gear in double bearing box ru...

Page 173: ...90 DP 1 95 1 Model 280 DP 280DP H1 290 DP 2 30 1 Model 280 DP PT 1 95 1 2 30 1 Model 290A DP 1 78 1 1 95 1 2 30 1 Weight Model Duoprop 58 kg 127 9 lb Gear backlash Lower gear measured on the wings of the inner propeller shaft nut 0 08 0 17 0 15 0 30 mm backlash in the gear 0 003 0 007 measured on the wings of the outer propeller shaft nut 0 11 0 34 0 20 0 35 mm backlash in the gear 0 008 0 014 Upp...

Page 174: ...g 10 7 5 Oil filler plug 35 25 Interm housing upper gear housing 38 28 Steering helmet attachment bolt 35 25 Pre stressing Input gear in double bearing box 280 290 5 10 N 1 102 2 205 lb Input gear in double bearing box run in gears 280 290 2 5 5 N 0 55 1 102 lb Input gear in double bearing box 290A 10 15 N 2 20 3 30 lb Input gear in double bearing box run in gears 290A 7 5 10 N 1 65 2 2 lb Lower g...

Page 175: ...on the gear wheel ratio 1 61 1 0 15 0 25 mm 0 006 0 010 ratio 1 89 1 0 08 0 18 mm 0 003 0 007 ratio 2 15 1 0 08 0 18 mm 0 003 0 007 Lower gear measured on the intermediate shaft spline joint 0 06 0 10 0 15 0 25 mm gear backlash in the gear 0 002 0 004 in Lubrication System Pump type Circulation pump for distribution of oil to all lubricating points Oil quality API GL51 Viscosity SAE 90 or 80W90 Oi...

Page 176: ... 15 11 Lower nut on vertical shaft 110 81 Bearing box with propeller shaft in gear housing 40 30 Interm housing lower gear housing 15 11 Oil drain plug 10 7 5 Oil filler plug 35 25 Interm housing upper gear housing 20 15 Steering helmet attachment bolt 35 25 Pre stressing Input gear in double bearing box 5 10 N 0 5 1 0 kp 1 102 2 205 lb Input gear in double bearing box run in gears 2 5 5 N 0 25 0 ...

Page 177: ...mm 0 003 0 007 in backlash in the gear Lower gear measured on the wings of the outer propeller shaft nut 0 11 0 34 0 20 0 35 mm 0 008 0 014 in backlash in the gear Upper gear measured directly on the gear ratio 1 95 1 and 1 78 1 0 15 0 25 mm 0 006 0 010 ratio 2 30 1 0 08 0 18 mm 0 003 0 070 Lubrication System Pump type Circulation pump for distribution of oil to all lubri cating points Oil quality...

Page 178: ... Lower nut on vertical shaft 110 81 Bearing box with propeller shaft in gear housing 40 30 Interm housing lower gear housing 15 11 Oil drain plug 10 7 5 Oil filler plug 35 25 Interm housing upper gear housing 20 15 Steering helmet attachment bolt 35 25 Prestressing Input gear in double bearing box 5 10 N 1 102 2 205 lb Input gear in double bearing box run in gears 2 5 5 N 0 55 1 102 lb Lower gear ...

Page 179: ...176 References to Service Bulletins Group No Date Concerning ...

Page 180: ... this page write your comments down and send them to us The address is at the bottom We would prefer you to write in English or Swedish From Refers to publication Publication No Date of issue Proposal motivation Date Signed AB Volvo Penta Technical Information Dept 42200 SE 405 08 Göteborg Sweden ...

Page 181: ...7731624 8 English 06 2003 ...

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Volvo Penta AQUAMATIC 280, Workshop Manual

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Summary of Contents for AQUAMATIC 280

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