Publ. No.

7797282 03-1999

Installation Instructions
Engines
30GSMEFS 30GSPEFS 43GLPEFS 43GIPEFS 50GLPEFS 50GIPEFS 57GSPEFS 57GSIPEFS 74GIPEFS 74GSIPEFS 82GSIPEFS DPX385XEFS DPX415XEFS

Transom Shield and Sterndrives

SX-M, -MACLT, -MDA, -MDB, -MHP, -MLT, -MTD DP-E; DP-S, -S1, -S2; DP-SM, -SMTD DPX-R; DPX-S, -S1

Safety Considerations
These instructions will alert you to certain things you should do very carefully. If you don't, you could hurt yourself or bystanders hurt the boat operator or bystanders damage the machinery Safety symbols appear next to information important to prevent you and others from being hurt.

symbol appears next to information important to keep machinery from being damaged.

IMPORTANT!
The safeguards and instructions appearing in this publication cannot cover all possible conditions or situations that occur. The person following these directions must use common sense, caution, and care.

Product Reference and Illustration

When reference is being made to a brand name, product, or specific tool, an equivalent product may be used in place of the referred to product. Substitute products used must have equivalent characteristics, including type, strength, and material. Incorrect substitution may result in product malfunction and possible injury to the operator and/or passengers. All photographs and illustrations used may not necessarily depict actual models or equipment, but are intended only for reference. Specifications used are based on the latest product information available at the time of publication.

Important! This batch with its accompanying instructions

is produced for Volvo Pentas service workshops, boat-builders, machine manufacturers and other authorized workshops which have personnel with qualified professional training. The installation instructions are only produced for professional use and are not intended for non-professional use. Volvo Penta will not assume any liability whatsoever for damage incurred, either damage to materials or personal injury, which may result if the installation instructions are not followed or if the work is carried out by non-professional personnel.

Vigtigt! Dette st med tilhrende monteringsvejledning

er blevet udviklet for Volvo Pentas servicevrksteder, bdebyggere, maskinproducenter og andre autoriserede vrksteder, som har medarbejdere med kvalificeret, faglig uddannelse. Monteringsvejledningen er udelukkende beregnet til professionel anvendelse og ikke til hobby- eller fritidsbrug. Volvo Penta ptager sig intet som helst ansvar for eventuelle skader p svel materiel som personer, som kan vre en flge af at monterings-vejledningens anvisninger ikke blev overholdt, eller hvis arbejdet blev udfrt af ikke-professionelt personale.

Wichtig! Dieser Satz mit vorliegender Einbauanleitung ist

fr Volvo Penta Kundendienst-werksttten, Werften, Maschinenbauer und fr andere ermchtigte Werksttten mit beruflich geschultem Personal vorgesehen. Die Einbauanleitung ist nur fr den berufsmigen Gebrauch vorgesehen und nicht fr unprofessionelle Anwendung gedacht. Volvo Penta bernimmt nicht die geringste Haftung fr irgendwelchen Schden an Personen oder Sachen, die als Folge einer Nichtbefolgung der Einbauanleitung oder wegen Ausfhrung der darin beschriebenen Arbeiten durch nicht beruflich geschulte Personen entstehen.

Trke! Tm sarja ja asennusohje on tarkoitettu Volvo

Pentan huoltokorjaamoille, veneenrakentajille, konevalmistajille ja muille valtuutetuille korjaamoille, joiden henkilkunta on saanut ptevn ammattikoulutuksen. Asennusohje on tarkoitettu ainoastaan ammattikyttn. Volvo Penta ei vastaa mahdollisista materiaali- tai henkilvahingoista, joita asennusohjeen laiminlyminen tai ammattitaidottoman henkilkunnan suorittama asennusty voi aiheuttaa.

Belangrijk!

Important ! Ce kit, avec instructions de montage, est destin aux ateliers de service Volvo Penta, aux constructeurs de bateaux et autres ateliers de construction agrs avec un personnel qualifi.
Les instructions de montage sont exclusivement conues pour une utilisation professionnelle. Volvo Penta se dgage de toute responsabilit pour dventuels endommagements, corporels ou matriels, rsultant du non respect des instructions ou dun travail effectu par un personnel non comptent.

Deze set met de bijgevoegde montageaanwijzing is ontwikkeld voor de werkplaatsen van Volvo Penta, botenbouwers, machinefabrikanten en overige bevoegde werkplaatsen, die personeel hebben met een gekwalificeerde vakopleiding. De montage-aanwijzing is alleen ontwikkeld voor professioneel gebruik en is niet bedoeld voor niet-professioneel gebruik. Volvo Penta neemt geen enkele verantwoordelijkheid op zich voor eventuele schade, zowel materile schade als persoonlijk letsel, die het gevolg kan zijn als de montage-aanwijzing niet wordt gevolgd, of als het werk wordt uitgevoerd door niet-vakkundig personeel.

Importante! El presente juego con las instrucciones de montaje se destina a los talleres de servicio Volvo Penta, constructores de embarcaciones y mquinas y a otros talleres autorizados que cuentan con personal capacitado.
Las instrucciones de montaje estn destinadas nicamente para uso profesional, por lo que Volvo Penta no aceptar responsabilidad alguna por cualquier dao, tanto personal como material, resultado de no haber seguido las instrucciones de montaje o de haber sido efectuado el trabajo por personal que no est debidamente capacitado.

Importante! Este jogo, juntamente com as respectivas

instrues de montagem, foi concebido para as oficinas de servio da Volvo Penta, construtores navais, construtores de mquinas e outras oficinas autorizadas, com pessoal devidamente formado. As instrues de montagem foram concebidas unicamente para utilizao profissional e no se destinam a utilizao no profissional. A Volvo Penta no se responsabiliza por quaisquer danos eventuais, tanto materiais como pessoais, que possam resultar no caso de as instrues de montagem no serem seguidas, ou se os trabalhos forem executados por pessoal no profissional.

Importante! Questo kit e le relative istruzioni di montaggio sono stati realizzati per le officine di servizio Volvo Penta, i cantieri, i fabbricanti di macchine e tutte le altre officine autorizzate il cui personale ha ricevuto un addestramento qualificato e specializzato.
Le istruzioni di montaggio sono state redatte esclusivamente per uso professionale e non sono adatte alluso non professionale. La Volvo Penta non si assume alcuna responsabilit per eventuali danni alle cose o alle persone, derivanti da trascuratezza nel seguire le istruzioni di montaggio oppure dallesecuzione dei lavori da parte di personale non qualificato.

Prosoxq! To periexmeno ayto toy paktoy maz me tiw

odhgew synarmolghshw poy to akoloyuon enai eidik epilegmno gia synergea srbiw thw Volvo Penta, nayphgea, kataskeyastw mhxann kai gia loip ejoysiodothmna synergea poy diautoyn ejeidikeymno prosvpik. Oi odhgew synarmolghshw proorzontai mno gia epaggelmatikq xrqsh kai den aposkopon gia xrqsh ap mh epaggelmatew. H Volvo Penta den analambnei apoltvw kamia eyunh gia piuanw zhmiw, tso ylikw so kai prosvpikw, poy mporon na proklhuon epeidq den akoloyuontai oi odhgew synarmolghshw q epeidq h ergasa ekteletai ap mh ejeidikeymno prosvpik.

Viktigt!

Denna sats med freliggande monteringsanvisning r framtagen fr Volvo Pentas serviceverkstder, btbyggare, maskintillverkare och vriga auktoriserade verkstder som har personal med kvalificerad fackutbildning. Monteringsanvisningen r enbart framtagen fr yrkesbruk och r inte avsedd fr icke yrkesmssig anvndning. Volvo Penta ptager sig inget som helst ansvar fr eventuella skador, svl materiella som personskador, som kan bli fljden om monteringsanvisningen ej fljs, eller om arbetet utfrs av icke yrkeskunnig personal.

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Service Policy . . . . . . . . . . . . . . . . . . . . . . . . 5 Warranty Responsibility . . . . . . . . . . . . . . . . . . . . 5 References, Illustrations and Specifications . 5 Safety Alert Symbols . . . . . . . . . . . . . . . . . . . . . . 5 Installation Procedures . . . . . . . . . . . . . . . . . . . . 5 Transom Shield . . . . . . . . . . . . . . . . . . . . . . . . . 6 Prepare for Installation . . . . . . . . . . . . . . . . . . . . 6 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sealants and Lubricants . . . . . . . . . . . . . . . . 6 Model Identification . . . . . . . . . . . . . . . . . . . . 7 Static Water Line . . . . . . . . . . . . . . . . . . . . . . 7 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . 7 Recommendations . . . . . . . . . . . . . . . . . . . . 7 External Power Steering . . . . . . . . . . . . . . . . . . . 7 Recommendations . . . . . . . . . . . . . . . . . . . . 7 Locate Transom Centerline . . . . . . . . . . . . . . . . . 8 Twin Engine Installation . . . . . . . . . . . . . . . . . . . 9 Locate Transom Baseline and X-Dimension . 9 Centerline Spacing . . . . . . . . . . . . . . . . . . . . 9 Procedure A: Transom Drill Fixture . . . . . . . 12 Procedure B: Transom Template . . . . . . . . 14 Finish Transom Cutout Area . . . . . . . . . . . . . . . 18 Install Transom Shield Assembly . . . . . . . . . . . 19 Install Trim/Tilt Pump Assembly . . . . . . . . . . . . 23 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Prepare for Installation . . . . . . . . . . . . . . . . 24 Required Tools and Equipment . . . . . . . . . . . . . 24 Locate Forward Engine Mount Holes . . . . . . . . 25 Install Steering Cylinder / Steering Tube . . . 27 Procedure A: Power Steering . . . . . . . . 27 Procedure B: Mechanical Steering . . . . 30 Exhaust Pipe Installation . . . . . . . . . . . . . . . . . . 32 Thru-Transom Exhaust Only . . . . . . . . . . . . 32 Thru-Gearcase Exhaust Only . . . . . . . . . . . 33 Install Drain Plugs . . . . . . . . . . . . . . . . . . . . . . . 33 Connecting Raw Water Pump Hoses . . . . . 34 Remove Engine from Pallet . . . . . . . . . . . . 34 Install and Align Engine . . . . . . . . . . . . . . . . 34 Install Cables and Hoses . . . . . . . . . . . . . . . . . . 36 Install Battery Cables . . . . . . . . . . . . . . . . . 36 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . 38 Install Power Steering Lines . . . . . . . . . . . . 38 Single Engine, or Starboard Engine of Dual Installations . . . . . . . . . . . . . . . . . . . . . 38 Port Engine of Dual Installations Only . 39 Throttle Cable Lengths . . . . . . . . . . . . . . . . 40 Remote control throttle cable: . . . . . . . . 40 Throttle Cable Installation . . . . . . . . . . . 40 General Information . . . . . . . . . . . . . . . . . . . . . . 41 Engine Combustion Air Inlet Size Requirements 41 Engine Compartment/Room Ventilation Air Inlet Size Requirements. . . . . . . . . . . . . . . . . . . 42 Battery Requirements . . . . . . . . . . . . . . . . . 42 Battery Connections . . . . . . . . . . . . . . . . . . 42 Prepare for Shipment . . . . . . . . . . . . . . . . . 43 Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Prepare for Installation . . . . . . . . . . . . . . . . 45 Special tools required: . . . . . . . . . . . . . 45 Sealants and Lubricants as Required: . 45 Installing Drive Unit . . . . . . . . . . . . . . . . . . . . . . 50 Check and Adjust Trim Sending Unit . . . . . . . . . 52 Shift Cable Installation . . . . . . . . . . . . . . . . 53 Remote control shift cable . . . . . . . . . . . . . 53 Check installation of shift cable . . . . . . . . . . . . . 53 All Models: . . . . . . . . . . . . . . . . . . . . . . . . . 53 Twin Installations, SX Models Only: . . . . . . 53 Check Remote Control Shift Cable Stroke . 53 Shift Cable Installation . . . . . . . . . . . . . . . . . . . . 54 Shift System Test . . . . . . . . . . . . . . . . . . . . 57 Start-in-Neutral-Only Test . . . . . . . . . . . . . . 57 Propeller Installation . . . . . . . . . . . . . . . . . . . . . 57 SX Models . . . . . . . . . . . . . . . . . . . . . . . . . 57 DP-S Models . . . . . . . . . . . . . . . . . . . . . . . . 58 Pre-delivery Checklist . . . . . . . . . . . . . . . . . . . . 59 Static Water Line Test . . . . . . . . . . . . . . . . . . . . 60 On-Water Tests and Adjustments . . . . . . . . . . . 61 Check Engine Operation . . . . . . . . . . . . . . . 61 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . 62 Models With Power Steering . . . . . . . . . . . 62 Models Without Power Steering . . . . . . . . . 62 Tie Bar Adjustment . . . . . . . . . . . . . . . . . . . 62 Duoprop Drive Unit Twin Installations: . . . . . . . 62

Introduction
This installation instruction covers Volvo Penta equipment manufactured by Volvo Penta to be used on Volvo Penta products. Any use other than those specified in these instructions may give unpredictable results. These instructions provide the installer with the necessary information to make a single or dual engine installation of a Volvo Penta sterndrive. Proper preparation is extremely helpful for efficient service work. A clean work area at the start of the job will minimize tools and parts becoming misplaced. Before you start work, gather all tools, instruments, and parts needed for the job. Interrupting a job to locate special tools or repair kits causes needless delay.

This sterndrive marine propulsion system, as manufactured, meets or exceeds all applicable U.S. Federal Regulations covering recreational boats as required under Title 46 of the United States Code enacted by Public Law 98-89, August 26, 1983. The requirements under this Code encompass all recreational boats to be sold in the United States, Guam, Puerto Rico, the Virgin Islands, American Samoa, the District of Columbia, the Northern Mariana Islands, and any other territories or possessions of the United States. Three technical booklets of special importance to help boat manufacturers understand and comply with these U.S. Federal Regulations are Electrical System Compliance Guideline, AD/ A-049-638 Fuel System Compliance Guideline, AD/A-047-767 Ventilation System Compliance Guideline, AD/A-114-507 These and other technical publications are available from the National Technical Information Service (NTIS), U.S. Department of Commerce, Springfield, Virginia 22161; (703) 487-4650 Telephone NTIS to obtain a quotation coding and cost of publication. This information must be included with your booklet order.

CAUTION Anyone who uses an installation

procedure or tool that is not recommended must first be satisfied that neither their nor the users safety will be jeopardized by the installation methods selected.

Service Policy
Whether within or following the warranty period, Volvo Penta has a constant interest in its products. It is Volvo Penta's policy to provide dealers with service knowledge so they can give professional service demanded by today's consumer. The Volvo Penta service schools, frequent mailing of service bulletins, letters and promotions, special tools, and these instructions represent Volvo Penta's efforts in giving consumers the best and most prompt service possible. If a service question does not appear to be answered in these instructions, you are invited to call, write, or e-mail the Volvo Penta Service Department for additional help. Always be sure to give complete information, including engine model and serial number. Be sure you are familiar with Volvo Penta's warranty. If you have any questions, call, write, or e-mail the Volvo Penta Service Department. If other than genuine Volvo Penta parts and components are used, Volvo Penta may refuse subsequent warranty claims involving that engine. When a brand-name product or particular tool is specified, another item may be used. However, the substitute must have equivalent characteristics, including type, strength, and material. You must determine if incorrect substitution could result in product malfunction and personal injury to anyone. To avoid hazards, any equivalent products used must meet all U.S. Coast Guard Safety Regulations and ABYC standards. Volvo Penta has specially-designed tools tp simplify some disassembly and assembly operations. These special tools are listed in this instruction. All Volvo Penta special tools may be ordered from Volvo Penta Parts Order.

References, Illustrations and Specifications

Volvo Penta reserves the right to make changes at anytime, without notice, to specifications, models, and procedures. Also, the right to change any specifications or parts at any time without incurring any obligation to equip same models manufactured prior to date of such change. All information, illustrations, and specifications contained in these instructions are based on the latest information available at the time of printing. The right is reserved to make changes at any time without notice. Photographs and illustrations used in this instruction may not depict actual models or equipment. The continuing accuracy of this installation instruction cannot be guaranteed. Use the general torque specification for all fasteners unless otherwise specified in the instructions. Carefully observe the safety alert symbols below for dangers, warnings, and cautions. They alert installers and operators of possible dangers or important information contained in this manual. Warnings alone do not eliminate hazards, nor are they a substitute for safe boat handling and proper accident prevention measures!

Safety Alert Symbols

DANGER Failure to comply with a danger symbol will result in serious injury or death to boat operator, boat occupants, and/or others.

WARNING Failure to comply with a warning may result in injury or death to boat operator, boat occupants and/or others.
CAUTION Failure to comply with a caution may result in failure or damage to the equipment. Note! Special attention should be used to prevent incorrect assembly or disassembly.

Warranty Responsibility
CAUTION It is the responsibility of the boat
manufacturer, dealer, or engine installer to position and install the sterndrive and engine properly. An installation that permits water to enter the engine through the exhaust manifold(s) will not be covered by warranty unless damage is due to defective part(s).

Installation Procedures
Proper installation is important for the safe, reliable operation of all mechanical products. In these instructions we recommend and describe effective procedures you should follow when installing Volvo Penta sterndrive products. Some of these methods require the use of tools especially designed for the purpose. These tools should be used whenever recommended.

Transom Shield

Transom Shield
Prepare for Installation
Follow these steps in the order listed to perform a complete installation of a Volvo Penta transom shield assembly: 1. Prepare for installation 2. Test static water line height 3. Steering system recommendations 4. External power steering recommendations 5. Locate transom centerline 6. Locate transom baseline and X-dimension 7. Drill and cut transom 8. Finish transom cutout area 9. Model identification 10. Install transom shield assembly 11. Install trim/tilt assembly Read installation instructions completely, and collect all tools, instruments, and parts needed for the job before you start work.

Special Tools
Transom Drill Fixture, P/N 3851081 or Transom Template All models except 7.4 GSI & 8.2 GSi, P/N 3850029 7.4 GSI & 8.2 GSi models only, P/N 3857256

Sealants and Lubricants

Volvo Penta water resistant grease, P/N 828250 White sealing compound for drives P/N 1141570

Before beginning the installation, it is the installers responsibility to determine that the boat transom meets the following requirements: Maximum transom thickness: 2-1/4 in. (57 mm) Minimum transom thickness: 1-3/4 in. (44 mm) Inside transom area must be flat within 1/8 in. (3.17 mm) Outside transom area must be flat within 1/16 in. (1.57 mm) Inside and outside transom area must be parallel within 1/8 in. (3.17 mm)

Tools
Wrenches and sockets, 1/4 in. to 1 in. Electric drill with 1/2 in. (12 mm) chuck Drill bits 1-1/32 in. (8.73 mm) 1/2 in. (13 mm) Electric reciprocating or saber saw (e.g. Sawzall) Hole saw 1 in. (25.5 mm) 1-3/4 in. (45 mm) Combination level/protractor Torque wrench Screwdrivers Carpenters square Protractor Drift punch Hammer Pliers set Portaline drilling fixture

2000 VPA/TSK

Transom Shield
Model Identification
All sterndrive system components most be matched for either single or dual engine installations. The engine, transom shield, and drive unit model numbers must correspond according to the Model Matrix shipped with the Sterndrive.

Steering System
Recommendations
Duoprop equipped, dual engine installation boats with a top speed of 60-70 MPH require a combination of internal and external tie bars. A dual trim limiter (P/N 3857242-6), should always be installed when a combination of internal and external tie bars are used to prevent high stresses from the difference in trim angles. (Such stresses may occur, for example, if only one drive is tilted.)

CAUTION Failure to properly match engine

and drive unit will result in poor boat performance, and risk damage to engine and drive because of incorrect drive gear ratio.

Static Water Line

Determine if the engine meets the static water line height requirements after the engine and drive unit have been installed in the boat. The boat must be in water with its recommended load capacity distributed aboard.

CAUTION An external tie bar must never be

used as the only tie bar, but must always be combined with an internal tie bar.

External Power Steering

Recommendations
External power steering is required for boats with a top speed of mote than 70 MPH or any application where the boat and sterndrive may occasionally come out of the water. External tie bars and external power steering systems can be obtained from:

CAUTION The static water line height must be

tested before the engine is started for the first time. This will prevent the ingestion of water into the engine and resultant damage. (To determine the static water line height, Follow the instructions in the Drive Unit Installation Instructions under On Water Tests and Adjustments.)

Mayfair Marine Opalocka, Florida The following part numbers apply: MM VOLSCSD (Single Sterndrive/Single Cylinder/Full Hydraulic) MM VOLDCSD (Single Sterndrive/Dual Cylinder/Full Hydraulic MM VOLDCDD (Dual Sterndrive/Dual Cylinder/Full Hydraulic

Note! An installation that permits water to enter

the engine through the exhaust manifold(s) will not be covered by warranty, unless damage is due to defective part(s).

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Transom Shield

Locate Transom Centerline

6

1. Draw a line parallel to the boat side at the port and starboard chines.

5 4 3 2 1 INCHES

162-01

2. Draw an intersecting line parallel to the boat bottom at the port and starboard chines. Lightly mark the points of intersection. These points will be the centers of arcs drawn to find the transom centerline.

Note! The vertical centerline of the transom is most accurately

found by using a beam compass. A workable beam compass may be made by clamping a pivot point and a pencil to a bar. A stiff wire with loops at each end for pivot point and pencil will also work, if used carefully.
INCH ES 1 2 3 4 5 6 7 8 9

162-02

3. Strike an are at the top of the transom from one chine point and an intersecting are from the other chine point without changing beam compass length. The exact same radius must be used to strike both arcs to locate the upper transom center point accurately. Repeat the procedure to locate the lower transom center point, with a different radius if necessary.
162-03

4. If the boat bottom is fiat or a very shallow V, a lower center point may be found by measuring across the transom from chine point to chine point and marking the midpoint on the transom.
162-04

5. Draw a straight vertical line through the upper and lower center points. This transom centerline will be used for the transom shield centerline on single engine installations and as a reference line on twin engine installations. For single engine transom layout, continue on to Locate Transom Baseline and X-Dimension.
162-05

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Transom Shield

Twin Engine Installation

Engine/Drive 3.0 SX 4.3 SX/DP 5.0 SX/DP 5.7 SX/DP 7.4 SX/DP 8.2 DP Recommended 29.25 in. (743 mm) 35.4 in. (890 mm) 34.25 in. (870 mm) 34.25 in. (870 mm) 35.9 in. (911 mm) 35.9 in. (911 mm) Minimum 26.5 in. (673 mm) 32.3 in. (820 mm) 31.5 in. (800 mm) 31.5 in. (800 mm) 33.1 in. (841 mm) 33.1 in. (841 mm)

Centerline Spacing

Note! The minimum engine centerline distance for twin engine installation determines the transom shield centerline and engine spacing. Use the following chart for all centerline dimensions.

6. Use a carpenters square to mark the transom. Place a mark at A of the selected engine centerline distance to port of the transom centerline. Place a second mark B at of the selected engine centerline distance to starboard of the transom centerline.

162-06

7. Make similar measurements from the transom centerline near the bottom of the boat to locate the bottom points.

162-07

8. Use a carpenters square or straight edge to connect both port and starboard transom shield centerline marks. Check the distance at both top and bottom to ensure the transom shield centerlines are equal distance from transom centerline used as a reference.
162-08

Locate Transom Baseline and X-Dimension

Note! The transom baseline is the horizontal centerline for the
transom shield fixture and template. Boat transom angle and anti-ventilation plate height need to be known to determine the transom baseline position on the transom. The X-dimension is the distance from the hull bottom to the intersection of the transom baseline (crankshaft centerline) and vertical centerline.

D C
162-09

1. The boats transom angle can be measured with several different protractors or shop devices. Two commonly used protractors are the machinists adjustable protractor and the universal plumb and level protractor. Both of these protractors can be obtained locally and should be used to determine the transom angle of the boat.

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Transom Shield
1A. Machinists Adjustable Protractor: Place a 4 ft. (1.2 m) straight edge E against the boat bottom or pad near the center of the transom. Do not place the straight edge on the keel. Place the protractors movable turret against the straight edge. Adjust the protractors straight edge C to fit the transom angle. Measure the transom angle directly from the protractor in number of degrees from perpendicular. Record the actual transom angle of the boat for later reference in selecting the X- dimension.

C E

162-10

1B. Universal Plumb and Level Protractor: Place a 4 ft. (1.2 m) straight edge on the boat bottom or pad near the center of the transom. Do not place the straight edge on the keel if the boat has one. Place the protractor on the straight edge. Level it by raising or lowering the front of the boat.

D E

162-11

3. With the boat in a level position, place the protractor against the transom. Record the transom angle reading for later reference in selecting the X-dimension.

162-12

4. Place a 4 ft. (1.2 m) straight edge along bottom of boat at transom shield vertical centerline for single engine installations, or at and for twin engine installations. Measure the dimension selected from the chart, from top of straight edge . Follow the transom angle to get an accurate measurement. Place a mark on the transom. This will become the transom shield horizontal baseline.

C B

A
162-14

3
5. Use a carpenters square to extend the transom shield baseline (X-dimension) to port and starboard perpendicular to the vertical centerline.

162-15

10

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Transom Shield

DUAL INSTALLATION
Refer to installation drawings for minimum center distance.

DP-S

Center line of the engine

SINGLE INSTALLATION

"X"

13" (1 0
SX

"-1 6
")

Measure "X" along slant of transom.

"X"

Center line of the engine

"X"

"X"

13" (1 0

"-1 6
")

162-13

The figures in the chart on this page will give an anti-ventilation plate height of in. above the boat bottom for a SX models and in. above the boat bottom for DP-S model. These dimension will give the optimum installation height for most applications. If changes are necessary, adjustment must be made using the in, figure for SX models and in, figure for DP-S models as a reference point. The angle of the transom must also be known before starting. If the optimum location of the anti-ventilation plate in relation to the boat bottom is unknown, use the following chart as a guide.

Transom Angle X-Dimension Degrees inches mm 13 10 13- /16 351 11 12 13 14 15 16 13- /64 13- /16 13- /32 14- /64 14- /32 14- /64
11 3 1 31 15 55

352 354 355 356 358 360

table.xls

Note! Above figures to be used in conjunction with the specific engine installation drawing.

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11

Transom Shield
Two devices and procedures can be used to drill and cut the boat transom. Follow either: Procedure A: Transom Drill Fixture, P/N 3851081, see below. A metal fixture is used to cut out transom. Procedure B: Transom Template, P/N 3850029 or 3857256. A paper template is used to cut out transom.

Note! Twin engine installations require two holes be cut in the transom. Either procedure for marking and
cutting the hole will work, but must be done twice, once for each hole. A new paper template must be used for the second cutout if Procedure B is used.

Procedure A: Transom Drill Fixture, P/N 3851081

B
1. Center punch transom at the intersection of the transom shield baseline (X-dimension) and vertical centerline . Use a Portalign drill guide to ensure drilling a perpendicular hole through the transom. Drill a 9/16 in. (14 mm) hole at the center punch point.

162-16

2. Align notches of drill fixture with vertical centerline and transom shield baseline (X-dimension) . Secure drill fixture to transom with 1/2 in. (13 mm) bolt, flat washers, and nut supplied with drill fixture. Install a wood screw in either one of the two small holes to keep the transom fixture from rotating.

B 2 F D

E F

162-17

3. Mark transom cutout area using the drill fixture as a guide.

162-18

4. Drill seven 9/16 in. (14.3 mm) holes

A
162-19

12

2000 VPA/TSK

Transom Shield

5. Drill two in. (6.4 mm) guide holes.

162-19a

8. 7.4Gi, 7.4GSI & 8.2GSI Models with SX-MHP transom shield Only: Drill two 9/16 in. (14.3 mm) holes A . Remove drill fixture from transom.

A
162-19

9. Draw a line (dotted line) around outside edge of saw pilot hole, and connect points D and E . This corner of lower transom cutout (shaded area) must be removed when making transom cutout.

D E
162-21

10. Draw a line connecting vertical lines on both sides of cutout.

162-22

2000 VPA/TSK

13

Transom Shield
11. Remove drill bit from 1-3/4 in. (45 mm) hole saw. Replace drill bit with a 6 in. (15.2 cm) long, 1/4 in. (6.4 mm) pilot rod (drill rod). Cut two 1-3/4 in. (45 mm) holes following the guide holes.

162-23

G
12. Use a straight edge to mark a horizontal line G across the top of the 1-3/4 in. (45 mm) holes. Cut transom following marked cutout. Use either a drilled 1-3/4 in. (45 mm) hole or-

H
162-24

inner 9/16 in. (14 mm) hole I as a starting point. Keep blade perpendicular (90) to transom. Proceed to Finish Transom Cutout Area found elsewhere in this instruction sheet.

Note! Cutting on the marked line is important. Cutting too far

inside will make the transom shield difficult to install. Cutting too far outside will weaken the transom shield stud mounting holes.
162-25

Procedure B: Transom Template

P/N 3850029, All Models Except 7.4Gi, 7.4GSi & 8.2 GSi P/N 3857256, 7.4 GSi & 8.2 GSi Models Only

1. Carefully cut out center diamond of template.

J
162-26

14

2000 VPA/TSK

Transom Shield
2. Position the transom template on the boat transom. Align the template centerlines and with the vertical centerline and the transom shield baseline (X-dimension) marked on the boat transom. Tape template securely to transom.

M 3 K L
162-27

3. Center punch lower template holes.

162-28

4. Center punch lower bolt holes.

162-29

5. Center punch tiller arm cutout holes.

162-30

2000 VPA/TSK

15

Transom Shield

6. Use a Portalign drill fixture or equivalent to drill the two 60 holes and the up to eight perpendicular 90 holes through the transom.

162-31

7. Attach a power drill to the drilling fixture. Drill two 1/4 in. (6.4 mm) pilot holes to a depth of 3/8 in. (9 mm) perpendicular to transom for the two 60 steering clearance holes. This will prevent the drill from walking when drilling at a 60 angle.

162-32

8. Adjust rods to attain a 60 angle to the transom, using a 30 triangle.

30

B
162-33

9. Drill the two 60 angle 1/4 in. (6.4 mm) guide holes at the pilot holes drilled in Step 5.

162-34

16

2000 VPA/TSK

Transom Shield

10 Remove drill bit from 1-3/4 in. (45 mm) hole saw and replace with a 6 in. (15.2 cm) long, 1/4 in. (6,4 mm) pilot rod (drill rod). Follow the guide holes with the pilot rod and cut two 1-3/4 in. (45 mm) holes.

D
162-35

11. 7.4 GSi & 8.2 GSi Models Only: Drill two perpendicular holes E using a 9/16 in. (14,3 mm) drill bit. Drill six perpendicular holes F using a 9/16 in. (14,3 mm) drill bit.

F
162-36

12. Drill two 1 in. (25 mm) holes at bottom of transom template for starter holes to cut out transom.

162-37

13. Cut transom following shaded area of template. Use a drilled 1- in. (45 mm) holeas a starting point. Keep blade perpendicular (90) to transom at all times.

Note! Cutting on the marked line is important. Cutting too far

inside will make the transom shield difficult to install. Cutting too far outside will weaken the transom shield stud mounting holes.

162.38

2000 VPA/TSK

17

Transom Shield
Or use a 1 in. (25 mm) hole as a starting point. Keep blade perpendicular (90) to transom at all times.

Note! Cutting on the marked line is important. Cutting too far

inside will make the transom shield difficult to install. Cutting too far outside will weaken the transom shield stud mounting holes.

Finish Transom Cutout Area

1. Clean and file off all rough saw blade marks. Chamfer bottom inside edge of cutout to clear exhaust pipe on boats with the maximum transom thickness of 2-1/4 in. (57 mm).

162-39

162-40

2. Round off sharp corners

of steering arm area.

J
162-41

3. Cut or file a channel K on inside edge of cutout to drain trapped water into the bilge. This will keep the transom dry and free from rot.

K
162-42

K
18

162-43

2000 VPA/TSK

Transom Shield

4. Seal transom opening with a suitable sealant to prevent water absorption and deterioration of transom.

162-44

Install Transom Shield Assembly

2 7 4

3 5
162-45

1. Remove protective packing.

Note! Do not remove tie straps from trim/tilt cylinders at this

time. They will be removed before installation of the drive unit. 2. Check contents of transom shield hardware kit:

Note! 7.4 GSi and 8.2 GSi models use two extra flat washers,
two long screws, and two seals.

3. Cut tie straps retaining the hoses and wires.

162-46

4. Remove and save nuts retaining trim/tilt pump assembly to transom shield. 5. Remove trim/tilt pump assembly from the transom shield.

162-47

2000 VPA/TSK

19

Transom Shield
6. Remove and discard packing hardware A from the transom shield studs. Make sure the outer transom seal B and exhaust outlet seal C , are properly seated in their grooves. Hydraulic line fittings D at the transom shields and pump should be tight and not leaking. Check the transom shield alignment tube E for nicks or burrs that would make installation difficult.

D A C E

A
162-48

7. 7.4 GSi and 82 GSi Models Only: Remove the backing from seals. Press the seals into position over the screw holes on the upper inside surface of the transom shield.

162-48a

8. Move transom shield assembly close to transom cutout. Place trim/tilt pump assembly and shift cable sleeve and connector assembly through transom cutout.

162-49

9. Install outer transom shield into cutout of transom. Guide studs through drilled holes in transom. Route the trim/tilt pump assembly lines over top of port stud next to water tube.

162-50

20

2000 VPA/TSK

Transom Shield

10. Apply a light coat of Volvo Penta water resistant grease, 828250-1, to inner transom plate alignment sleeve. Apply white sealing compound for drives to all transom shield studs.

162-51

A B 2 5
2, 4

11. All models except 7.4 GSi & 8.2 GSi: Install inner transom plate over steering arm and water tube. Route trim/tilt sending wire through inner transom plate. Position trim/tilt hydraulic lines A in channel on port side of transom shield. Install flat side of bearing plate 3 against transom. Install three flat washers 2 and four lock nuts 5 and one lock nut B retained from trim pump. Do not tighten at this time.

2 3
162-52

B, 5

A
2, 5

12. 7.4 GSi & 8.2 GSi models only: Install inner transom plate over steering arm and water tube. Route trim/tilt sending wire through inner transom plate. Position trim/tilt hydraulic lines in channel A on port side of transom shield. Install flat side of bearing plate 3 against transom. Install five flat washers, 2 two long screws 4 coated with white sealing compound P/N 828250, and four lock nuts 5 and one lock nut B retained from trim pump. Do not tighten at this time.

2, 5

5
162-53

C 2 B
162-54

13. Attach ground lead C to remaining transom shield stud. Install last washer 2 and one lock nut B retained from trim pump. Do not tighten at this time.

2000 VPA/TSK

21

Transom Shield
14. Apply sealing compound P/N 828250 to threads of alignment screws 1 . Install and tighten alignment screws until head contacts the inner transom plate. Do not tighten screws at this time.

Note! The alignment screws must contact the transom plate or

the threads may be damaged in the final tightening operation.

162-55

15. All models except 7.4 GSI & 8.2 GSi: Tighten the six lock nuts in a cross pattern, as shown, starting from center of inner transom plate. Tighten to 20-25 ft. lb. (27-34 Nm).

6 2 4
16. 7.4 GSi & 8.2 GSi models only: Tighten the six lock nuts and two long screws in a cross pattern, as shown, starting from center of inner transom plate. Tighten to 20-25 ft. lb. (27-34 Nm).

3 1 5
162-56

6 3 2 8

7 1 4 5
162-57

17. Tighten the two alignment screws Nm).

to 12-14 ft. lb. (16-19

162-58

22

2000 VPA/TSK

Transom Shield
18. Attach inner transom plate ground strap to steering arm with washer and screw.

6 7

162-59

Install Trim/Tilt Pump Assembly

1. Position trim/tilt pump assembly in an area accessible for future service. Pump may be positioned on the transom or on a stringer. Hold trim/tilt pump in selected area with oil reservoir on the bottom. Mark the two lag screw mounting holes.

CAUTION Be sure the hydraulic hoses are routed away

from the steering arm and will not chafe against hoses belts or wires.

162-60

2. Center punch holes. Place a piece of tape 1 in. (25 mm) from the tip of a 7/32 in. (5.5 mm) drill bit to prevent drilling through the transom and to ensure the proper pilot hole depth. Drill pilot hole to depth of the tape.

162-61

3. Install trim/tilt pump assembly to transom and secure with two 5/16 in. x 1-1/4 in. (7.94 mm x 31.75 mm) lag screws, available locally. Tighten the screws securely.

162-62

4. Remove reservoir cap. Remove and discard shipping plug. Install cap and tighten securely.

2000 VPA/TSK

23

Engine

Engine
Proper installation is important for the safe, reliable operation of all mechanical products. In these instructions we recommend and describe effective procedures you should follow when installing Volvo Penta sterndrive products. Some of these methods require the use of tools especially designed for the purpose. These tools should be used whenever recommended. Follow these steps in the order listed to perform a complete installation of a Volvo Penta engine assembly: 1. Prepare for installation 2. Test static water line height 3. Locate forward engine mount holes 4. Install steering cylinder or tube 5. Exhaust pipe installation 6. Install drain plugs 7. Remove engine from pallet 8. Install battery cables 9. Shift and throttle cable lengths 10. Shift cable installation 11. Install and align engines 12. Install cables and hoses 13. Install power steering lines

Required Tools and Equipment

Special Tools: Engine Mount Drill Fixture, P/N 3851082-2, for V6 and V8 models Alignment Tool, (3851083-0) Universal Drive Handle (3850609-3) Additional Equipment Required: Steering wheel, helm, and cable Remote control, throttle, & shift cables Fuel system Instrument/trim harness assembly Emergency stop switch Battery cables

Sealants and Lubricants: Volvo Penta water resistant grease (828250-1) Volvo Penta white sealing compound for drives (1141570-0)

CAUTION
Test the static water line height before you start the engine for the first time. This will prevent the ingestion of water into the engine and resultant damage. Determine if the engine meets the static water line height requirements after the engine and drive units have been installed in the boat. The boat must be in water with its recommended load capacity distributed aboard. Follow the instructions in the Drive Unit Installation Instructions under the section titled, On Water Tests and Adjustments.

Prepare for Installation

Read installation instructions completely, and collect all tools, instruments, and parts needed for the job before you start work. Regular Tools: Wrenches and sockets, in. to 1 in. Electric drill with in. (12 mm) chuck Drill bits 11/32 in. (8.73 mm) in. (13 mm) Torque wrench Screwdrivers Drift punch Hammer Pliers set Hoist and sling with a minimum capacity rating of 1,500 lb. (680 kg)

CAUTION
An installation that permits water to enter the engine through the exhaust manifold will not be covered by warranty, unless damage is due to defective part(s).

24

2000 VPA/eng

Engine

Locate Forward Engine Mount Holes

1. On the drawing below, select the letter that corresponds to the engine model being installed, for the location of the forward engine mount pads. The dimension locates the center of the forward engine mount pads.
A

3.0 and V6 models . . . . . . . 16 in. (41.3 cm) V8 models . . . . . . . . . . . . . 20 in. (52.7 cm) Rear engine mount positions V6 and V8 front mount centerline is 11 in. (28.6 cm) to port and starboard of the engine centerline.

B C
D

B A

D C D

A B

2000 VPA/eng

25

Engine
2. Check rear engine mounts and hardware: Ref. 1 2 3 Name of Part Mounting Screw Washer Rear Engine Mount Qty. 4 4 2

1 2 3
15045

3. Secure rear engine mounts to transom bracket with washers and screws. Tighten screws to 20-25 ft. lb. (27-34 Nm).

2
33989

The engine mount drill fixture (3851082-2) has two functions: Locate or check the engine front mount pad height and angle. Locate front engine mount pilot holes.

B C A
33988

Note! The drill fixture is used to locate the forward engine mount holes for all models EXCEPT the 3.0 liter models.
4. Install drill fixture on rear engine mounts of inner transom plate. Center steering arm. Attach height fingers onto inner transom plate.

5. Position engine mount pads in. (6.35 mm) below bottom of drill fixture feet. Mark and secure pads to boat.

6. Select correct guide holes for the engine being installed. Drill four 11/32-in. (8.73 mm) pilot holes to a depth of 2 in. (63 mm).
D E

3.0 and 4.3 models V8 models

26

zy
, | z y
, | 
D E

18145

31574

2000 VPA/eng

Engine
7. Remove engine mount drill fixture from inner transom plate. Drill a -in. (13 mm) diameter counter bore hole, not to exceed in. (13 mm) in depth, through each pilot hole.

2988

Install Steering Cylinder / Steering Tube

The sterndrive must be coupled to a mechanical push-pull cable steering system. The boats steering system is important for control of the boat. It is also critical to the safety of persons in the boat or in its general area. We recommend that the installer follow the American Boat and Yacht Councils Safety Standards P-17 and P-22 for all aspects of the steering system to ensure that each component meets the minimum requirements. To obtain a copy of the current ABYC Standards P-17 and P-22, write to American Boat and Yacht Council 3069 Solomons Island Road Edgewater, MD 21037 U.S.A. Phone: 410/956-1050 Fax: 410/956-2737 The helm, steering wheel, and steering cable should be installed following the steering system manufacturers installation instructions and specifications. There are two types of steering systems: power steering and mechanical steering. For their installation, follow either Procedure A (Power Steering), or Procedure B (Mechanical Steering).

Procedure A: Power Steering

1 6

Note!

Accessibility may require the steering cable be installed prior to installation of the power steering cylinder. Make this determination before proceeding. If this is the case, make the necessary modifications to the following procedures.

1. Remove power steering box from engine box shelf and check contents of kit: Ref. 1 2 3 4 5 6 Name of Part Bolt Large Cotter Pin Cotter Pin Pin Pin Cylinder Assembly Qty. 2 2 2 1 1

33995

2000 VPA/eng

27

Engine

2. Install anchor bolts som plate.

flush with the inside of the inner tran-

33986

3. Apply Volvo Penta water resistant grease (828250-1) to both bushings A of steering cylinder.

A
23946

4. Install steering cylinder assembly 6 into inner transom plate. Align bushings of steering cylinder with anchor bolts. As the anchor bolts are tightened, make sure they pilot into the bushings. Tighten both anchor bolts to 40-45 ft. lb. (54-61 Nm).

CAUTION If anchor bolts do not align with steering cylinder mounting holes, the mounting bosses on transom plate will break when bolts are tightened.

6
23944

5. Install cotter pins 2 through holes in transom plate from transom side. Spread prongs of cotter pins to secure anchor bolts.

2
23943

6. Apply Volvo Penta water resistant grease (828250-1) to large pin 4 . Pull hydraulic arm assembly B over steering arm. Align holes and install large pin 4 from top of arm. Install cotter pin 3 . Spread prongs of cotter pin to secure large pin.

C 3
23942

28

2000 VPA/eng

Engine

6. Remove both protective plastic plugs tube.

and

from steering

F
7. Turn the steering wheel to fully extend the steering cable ram. Lubricate the full length of the steering ram with Volvo Penta water resistant grease (828250-1). 8. Retract steering ram and install into steering tube.

23940

G
9. Hold anchor nut back on cable casing to seat steering cable in end of steering tube. 10. Push steering cable against end of steering tube. Thread anchor nut onto tube until anchor nut bottoms on end of steering tube.

23957

H
11. Hold the steering tube with a wrench. Attach a crowfoot wrench to a torque wrench at a 90 angle. Tighten the steering cable anchor nut to 120 in. lb. (14 Nm).

23956

12. Turn steering wheel to extend ram. Align hole of steering cable ram with hole of hydraulic arm assembly. Apply Volvo Penta water resistant grease (828250-1) to small pin. Install pin from top of arm through cable hole. Install cotter pin). Spread prongs of cotter pin to secure small pin. Continue to Exhaust Pipe Installation.

F
2000 VPA/eng

3
23955

29

Engine
Procedure B: Mechanical Steering Note: Accessibility may require the steering cable be installed prior to installation of the mechanical steering tube and bushing assembly. Make this determination before proceeding. If this is the case, make the necessary modifications to the following procedures.
1. Check contents of the mechanical steering kit: Ref.
1 2 3 4 5 6

1 6

3 4 5

Name of Part Anchor Bolt Large Cotter Pin Pin Small Cotter Pin Steering Pin Bushing Tube Anchor and Bushing Assy

33996

2. Install anchor bolts flush with the inside of the inner transom plate.
33986

3. Apply Volvo Penta water resistant grease (828250-1) to both anchor block bushings.

33985

4. Position anchor block inside transom plate. Align bushings with anchor bolts. As the anchor bolts are tightened, make sure they pilot into the bushings. Tighten both anchor bolts to 40-45 ft. lb. (54-61 Nm).

CAUTION If anchor bolts do not align with steering cylinder mounting holes, the mounting bosses on transom plate will break when bolts are tightened.

33982

5. Install cotter pins through holes in transom plate. Spread prongs of cotter pins to secure anchor bolts.

2
33981

30

2000 VPA/eng

Engine

6. Turn the steering wheel to fully extend the steering cable ram. Lubricate the full length of the steering ram with Volvo Penta water resistant grease (828250-1). 7. Retract steering cable ram and insert into steering tube. Hold anchor nut back on cable casing to seat steering cable in end of steering tube. Make certain it is fully seated.
33980

8. Thread anchor nut onto tube until anchor nut bottoms on end of steering tube.

B
9. Attach a crowfoot wrench to a torque wrench at a 90 angle. Tighten the steering cable anchor nut to 120 in. lb. (14 Nm).

33979

5 5
18640

10. Turn steering wheel to extend ram. Install steering pin bushings in top and bottom holes of steering arm.

3
11. Apply Volvo Penta water resistant grease (828250-1) to pin. Install steering arm pin down through top steering arm bushing, steering cable ram, and bottom bushing.

18639

12. Install cotter pin through steering arm pin. Spread prongs of cotter pin to secure steering arm pin.

4
18638

2000 VPA/eng

31

Engine
13. Turn steering wheel lock-to-lock. Full steering arm travel must be present when fully extending and retracting the steering cable ram. Steering arm must not contact inside of transom cutout in either direction. Center steering wheel and check centering of steering arm. 14. If adjustment is necessary, refer to Steering Section of appropriate service manual.

33971

Exhaust Pipe Installation

33972

1. Remove cardboard box, plastic top and supports from engine and pallet. 2. Determine if the boat will have thru-transom or thru-gearcase exhaust, and refer to the appropriate following section.

Note! All Volvo Penta sterndrive models meet state and local
laws for noise pollution when they leave the factory. Modification of the exhaust system that alters the noise level of the engine is the responsibility of the person modifying the system.

A
33970

Thru-Transom Exhaust Only

1. Inspect seal around transom shield exhaust opening to be certain it is within its groove. 2. Install the exhaust block-off plate kit (3850889-1). Coat the four screws provided with the kit with Volvo Penta white sealing compound for drives and install them. Tighten the screws to 22-25 ft. lb. (30-34 Nm).

CAUTION Use only the screws provided with the kit. Use of
any other length screws could allow water entry into the boat. 3. The exhaust hose between the high-rise elbow and the thru-transom fitting must have a in. (12.7 mm) drop for every 12 in. (30.5 cm) of exhaust hose length.
33966

CAUTION A drop of less than in. (12.7 mm) can allow

water to flow back into the engine and cause severe internal damage. This damage will not be covered under warranty. Follow the manufacturers instructions for installation of the thru-transom hardware kit. Install thru-transom exhaust system.

33964

32

2000 VPA/eng

Engine
Thru-Gearcase Exhaust Only
1. Loosen two upper hose clamps on each end of exhaust pipe. For ease of removing exhaust pipe, spray under upper (loose) end of hoses with water. Cut tie strap securing the exhaust pipe to the plastic pallet, and pull exhaust pipe off engine. 2. Check exhaust pipe mounting screws: Ref.
18421

Name of Part Exhaust Pipe Mounting Screws

Qty. 4

3. Check flapper valve position and operation. Long lip must be down and it should pivot with ease. 4. Inspect exhaust seal of transom shield to be certain it is within its groove.

A
33970

5. Position bottom of exhaust pipe against bottom of exhaust seal. Apply white sealing compound for drives to the four exhaust pipe mounting screws. Hold pipe against exhaust opening without disturbing the seal, then install and tighten the four screws to 20-25 ft. lb. (27-34 Nm).

33962

Install Drain Plugs

All drain plugs, drain caps, hose clamps, and the positive (B+) battery cable protective cover are enclosed in a bag. If the engine is going to be water tested, install the drain plugs and drain caps while engine is resting on the pallet. 3.0 liter models only: Install drain plugs into exhaust manifold and engine block. All V-6 and V-8 models: Install drain plugs into port and starboard engine block, and drain caps or plugs onto exhaust manifold drain locations. Secure caps with hose clamps. EFI models only: If lower water hose has been removed from MOAS, reinstall and secure with hose clamp.

23913

Note! Before shipping engine after it has been water tested,

Remove the drain plugs and raw water pump hoses, drain all water from the engine and manifolds. Enclose drain plugs and hose clamps in a separate bag and attach them to the engine for shipment.

34102

2000 VPA/eng

33

Engine Connecting Raw Water Pump Hoses

Install the lower raw water pump hose connection to the thermostat housing hose. Connect the upper hose connection to the transom shield hose.

CAUTION If hoses are connected incorrectly, the engine could be severely damaged.

H
33857

Remove Engine from Pallet

1. Remove nuts and flat washers securing engine to pallet. 2. Use a lifting sling and hoist with a minimum capacity of 1,500 lb. (680 kg). Attach hoist to lifting brackets of engine.

DANGER Do not use the alignment eye attached to the

thermostat housing A as a lifting eye to suspend the engine during installation. The alignment eye will not support the weight of the engine.
33960

The lifting eye adjacent to the outboard starboard position of the thermostat housing should be used for engine suspension during installation. The alignment eye, attached to the thermostat housing, is only intended to help maneuver the engine during drive system alignment. Lift and level engine.

33959

Install and Align Engine

1. Check engine mount hardware: Ref.
1 2 3

1
Qty. 1 2 2

Name of Part Tie Strap Rear Mount Locknut Rear Mount Flat Washer

2 3
46339

2. Lower engine onto rear engine mounts.

2890

34

2000 VPA/eng

Engine
3. Install flat washer 3 into recess of engine bracket and secure to mount with a locknut 2 . Tighten locknut to 28-30 ft. lb. (11 Nm).

2 3

CAUTION DO NOT use an impact type power wrench to

tighten the rear engine mounting nuts. Thread damage will occur and make nut removal difficult.

2912

H
47547

4. Correct engine alignment is essential to engine drive train Use Alignment Tool, P/N 3851083-0 H , with Universal Handle, 3850609-3 G , to test engine alignment. Slide alignment tool through driveshaft gimbal bearing. Reposition the engine until alignment tool engages engine coupler. If the alignment tool binds going into engine coupler, the engine must be adjusted up or down, or side to side, as required, until alignment tool slides in and out of engine coupler with ease.

Note! After alignment has been completed, do not disturb

engine position.

A B

5. Loosen middle nut B on engine mount stud(s). Adjust the front engine mounts until they rest on the boats mounting pad(s). 6. While holding middle nut with an open end wrench, tighten the upper nut to 100-120 ft. lb. (135-165 Nm). After mounts have been properly adjusted and tightened, fully release engine from hoist. Recheck engine alignment Step 4, and make further adjustments if necessary.
18568

7.

Obtain locally four in. x 3 in. (12.7 mm x 76.2 mm) lag screws and four (12.7 mm) flat washers. Slide flat washers onto forward mount lag screws. Apply a coating of a high quality marine caulk to the threads of the screws. Install and tighten each screw until the hex head and washer make firm contact with the engine mount.

8. Tighten each lag screw an additional to turn to ensure each is engaged securely. Lag screw thread engagement must be secure. Failure to have secure thread engagement could cause engine to come loose.
29797

2000 VPA/eng

35

Engine Install Cables and Hoses

1. Slide exhaust hoses up onto exhaust elbows. Exhaust bellows must be installed on exhaust elbow far enough to allow the two hose clamps to firmly grip exhaust elbow. Position all hose clamps between ribs of exhaust hoses and tighten securely.

CAUTION DO NOT install hose clamps in expanded area

of hoses. Cooling system water flow will be restricted, and engine damage due to overheating will occur if the clamps are improperly installed.

A
31561

Install Battery Cables

1. Determine distance from engine to battery and select battery cables of the correct gauge wire. Do not use aluminum battery cables; each battery cable must be a copper-stranded conductor. 0 to 10 ft. (3.05 m) require a 1/0 AWG (90 MWG) cable 10 to 15 ft. (3.05 to 4.6 m) require a 2/0 AWG (100 MWG) cable 15 to 20 ft. (4.6 to 6.1 m) require a 4/0 AWG (130 MWG) cable 2. Install the red positive (B+) battery cable to starter solenoid terminal, and secure with lock washer and nut. Position protective cover over terminal.

C
29809

D
3. 3.0 liter models: Secure inner transom plate ground wire to flywheel housing screw D .

28571

3. V-6 and V-8 Models: Install inner transom plate ground wire to engine ground stud E and secure with lock washer and nut.

18404

36

2000 VPA/eng

Engine
4. Loosen water inlet hose clamp and slide back onto hose. Lightly lubricate inside of water inlet hose and install onto inlet tube. Position the clamp on inlet hose and tighten securely. Ensure the water inlet hose from the transom shield to the oil cooler is positioned away from the steering mechanism or steering control could be lost.

F
31467

Note! If inlet hose is not installed properly, underside of hose

may collapse. This would restrict water flow to the engine and cause overheating. Check underside of hose for proper installation and adjust hose as required. Tighten hose clamp securely.

24207

5. Push round connector of trim/tilt sender into connector of engine harness and secure with wire retainer. Secure trim/tilt sender wire to water inlet hose with tie strap.

H
24208

6. Align round plastic two-wire plug of trim/tilt motor with engine harness receptacle, push together to lock.

31461

7. Apply a light coat of Volvo Penta water resistant grease (828250-1) to trim/tilt plug. Align marks on plug and receptacle and press together. Route the instrument cable receptacle to join engine cable plug on engine. Be sure cable is routed to prevent cutting or chafing on any sharp object or moving engine component which could result in an electrical short, and contribute to fire and explosion in the engine compartment.
29790

2000 VPA/eng

37

Engine
8. Loosen hose clamp on large round engine cable plug and apply a light coat of Volvo Penta water resistant grease (828250-1) to plug. Align terminals of plug and receptacle and press together. Slide hose clamp over connector junction and tighten securely.

Fuel System
CAUTION U.S. Coast Guard regulations require installation
of an antisiphon valve in any installation in which any portion of the fuel supply line is below the top of the fuel tank. An adequately sized antisiphon valve must be used to prevent fuel flow restriction.
33729

DANGER Use only fuel hoses approved for marine use, and make certain all fuel line connections are leak free. Fuel leakage can result in fire or explosion. Make sure fuel line is routed properly to prevent damage from belts and pulleys.
9. EFI Engines: The fuel supply hose to the engine requires a minimum inside diameter of 3/8 in. (10 mm). Remove plastic protective plug from fuel inlet of the MOAS filter/pump assembly. Install 3/8 in. x in. NPTF fitting, using pipe sealant on threads. Securely attach boat fuel line to fitting.

29830a

10. Carbureted Engines: The fuel supply hose to the engine requires a minimum inside diameter of 3/8 in. (10 mm). Remove plastic protective plug from fuel inlet of fuel filter. Install 3/8 in. x in. NPTF fitting, using pipe sealant on threads. Securely attach boat fuel line to fitting.

29830

Install Power Steering Lines

Single Engine, or Starboard Engine of Dual Installations
1. Cut tie strap retaining hydraulic hoses and coupler.

CAUTION Route the power steering hoses away from

steering arm, exhaust pipes or belts that may chafe or entagle the hoses. Be sure the hoses are secured so they cannot get tangled in the steering mechanism and cause a loss of sttering.

23968

38

2000 VPA/eng

Engine

2. Remove small hose fitting from coupler. Remove small protective plastic cover B from steering cylinder. Attach small hose fitting to actuator.

23953

C
3. Remove large hose fitting from coupler. Remove large protective plastic cover C from steering cylinder. Attach large hose fitting to actuator.

23951

4. Tighten small hose fitting to 10-12 ft. lb. (14-16 Nm).

23963

5. Tighten large hose fitting to 15-17 ft. lb. (20-23 Nm).

23962

Port Engine of Dual Installations Only

Do not cut strap supporting both steering hoses. Do not remove power steering pump belt. Make sure that the hoses are clear of belts and pulleys and properly secured with the tie strap. Tighten small hose fitting to 10-12 ft. lb. (13.6-16.3 Nm). Tighten large hose fitting to 15-17 ft. lb. (20,3-23 Nm).

Note! If engine is run or tested, refill power steering reservoir

with power steering fluid supplied with engine. If engine is not run or tested, ship fluid with the boat.
31472

2000 VPA/eng

39

Engine Throttle Cable Lengths

Measure the proposed route of the remote control shift and throttle cables. All bends must have a radius greater than 6 inches (15.2 cm).

Remote control throttle cable:

Add D + E + F plus 4 in. (10.1 cm), ( F is to center of throttle arm pin). Round up to next cable length.

CAUTION Remote control shift and throttle cables must be

SAE type cables. When removing shift and throttle cables from the packing box, DO NOT bend the cables tighter than a 6 inch radius.

Check installation of throttle cable. Throttle cable should PULL to open and PUSH to close.

D F E
DR4939

5.0Gi 5.7GSi

Throttle Cable Installation

V6 and Small Block V8 Models Only: The engine throttle cable anchor block bracket has several sets of anchor block holes. The sets of holes marked with a V are used for Volvo Penta engines. The set of holes marked GSI are for 5.0 and 5.7 liter EFI models. The set of holes marked 43 are for 4.3 liter 2V (2 barrel) and 4V (4 barrel) carburetor models. Holes are for all 5.0 and 5.7 liter, 2V and 4V carburetor models. The anchor block will be set at the correct position from the factory for your particular engine. 1. Move remote control handle to the NEUTRAL detent position. Turn propeller shaft and shift into the forward gear detent position, and then pull HALFWAY BACK towards NEUTRAL. This positions the control for proper throttle cable adjustment. Failure to follow this procedure can bind the shift linkage in the control, and produce hard shifting.
5.0GL

4.3GL 4.3GS

5.7GS

DRC7279

E
2. Align internal bosses of trunnion with throttle cable groove Press trunnion on throttle cable until seated.

E
34751

40

2000 VPA/eng

Engine

C B A

3. Install open end of trunnion in anchor block. Install screw in anchor block and position throttle cable assembly in selected set of holes. Lock nut must be against the anchor bracket, tighten it securely.

DR4977

4. Install throttle cable connector L onto the throttle cable. Pull connector forward to remove all end play from remote control throttle cable, then turn the connector in until hole aligns with the throttle arm.

N
DR4978

CAUTION Throttle cable connector

must have a minimum of 9 full turns or in. of throttle cable thread engagement. If throttle arm connector hole cannot be adjusted to align with the throttle arm, check for proper cable installation in the remote control box.
L P

6. Install connector onto throttle arm. Install washer and cotter pin, and spread prongs of cotter pin O . Tighten the jam nut against the connector.

O
DR4979

General Information
Engine Combustion Air Inlet Size Requirements
Note! The engine consumes a certain amount of air for the combustion process, which requires a certain minimum area for the air flow. The area can be calculated using the one of the following formulas: For gasoline engines only

Area in inches2 = 0.16 x engine power output in HP

For metric calculations

1.38 x engine power output in kW = Area in cm2

The value applies for nonrestricted intake and up to 3.3 feet of duct length with only one 90 bend. The bending radius should be at least twice the diameter. If longer ducts or more bends are used, the area is corrected by multiplying the coefficient from the table below.

Number of bends 1 2 3 3.3 (1) 1 1.39

Feet (meters) of duct length 6.6 (2) 9.8 (3) 13.1 (4) 1.04 1.09 1.13 1.41 1.43 1.45 1.7 1.72 1.74

16.4 (5) 1.2 1.49 1.78

2000 VPA/eng

41

Engine Engine Compartment/Room Ventilation Air Inlet Size Requirements.

Note: To keep the engine compartment/room temperature down to permitted values, a great deal of the radiant heat must be transported out or the engine compartment/room.
The same dimension must be chosen for the inlet and outlet ducts to achieve low flow speeds and noise levels. The area for the inlet air can be calculated using the one of the following formulas: For gasoline engines only

Area in inches2 = 0.19 x engine power output in HP

For metric calculations

1.65 x engine power output in kW = Area in cm2

Battery Requirements
WARNING Batteries should be handled with care. If electrolyte contacts any part of the body, immediately flush the exposed area with water and seek medical attention as soon as possible.

Note! Read and understand the information supplied with your

battery BEFORE you begin installation. Batteries must be heavy-duty marine construction and either vented/refillable, or maintenance-free with a CCA or INCA rating. 3.0 GS, 4.3 GL and GS models only: Use a 12 volt battery having a minimum rating of 360 Cold Cranking Amps at 0F (18C), and a 115 minute reserve capacity rating at 80F (27C). All other models: Use a 12 volt battery having a minimum rating of 650 Cold Cranking Amps at 0F (-1 8 C), and a 165 minute reserve capacity rating at 80F (27 C).

Battery Connections
CAUTION Use bolts or nuts to secure battery cables to the
battery terminals. Do not use wing nuts, even if they were supplied with the battery. Wing nuts do not provide a secure connection for battery cables. Loose connections could cause permanent damage to electrical components. An internal star lock washer must be used with either a nut or screw to secure battery cables to the battery.

35247

CAUTION Service electrical components only while the

engine is not running. Be careful when identifying positive and negative battery cables and terminals. If you touch the wrong terminal with a battery cable, even briefly, the engines electrical system could be damaged.

DR4925

42

2000 VPA/eng

Engine
CAUTION The key switch must be in the OFF position to
safeguard against permanent damage to electrical components while connecting or disconnecting the battery cables. Connect the B+ starter solenoid cable to the positive B+ battery terminal. Position protective cover over terminal. This will provide current to the entire engine and instrument panel electrical system.

CAUTION The battery terminal connections must always be

insulated. Install protective covers if the battery mounting system does not cover the connections. This will help prevent shorting or arcing at the battery terminals.

Note! Connect the black engine ground cable to the negative

battery terminal. The engine electrical system will be operable when this connection is made.

Prepare for Shipment

1. If the Sterndrive will not be installed before shipment, make sure the paper or plastic gimbal housing cover is in place to prevent damage during shipment. This cover is part of the packing material shipped with the transom shield and is removed when the drive unit is installed. 2. If engine was water tested, and is to be stored or shipped, remove all water drain petcocks and rubber drain caps from engine. Make sure all water is removed from engine and manifolds.

H
33857

CAUTION V-6 Models: Remove the drin plug from starboard front of the intake manifold and tilt engine forward to compltely drain the water from the intake manifold. Any water left in the intake could freeze and cause engine damage. Freeze damage is not covered under Volvo Pentas Limited Warranty. 3. Remove and drain hose from the raw water pump to the thermostat housing. Crank engine for approximately 2 seconds (DO NOT START). This will purge the water from the raw water pump.

33858

4. Reconnect the hose. Tighten hose clamp securely. 5. Store all fittings in bag and attach to engine. Refill power steering reservoir with power steering fluid supplied with engine. If engine is not run or tested, ship fluid with the boat. 6. Check the engine, transom shield, and drive unit for the correct model numbers before shipping the boat (see separate sheet shipped with the drive unit.)

CAUTION Failure to properly match engine and drive unit

will result in poor boat performance, and risk damage to engine and drive because of incorrect drive gear ratio.

GR991020

2000 VPA/eng

43

Sterndrive

Sterndrive
Proper installation is important for the safe, reliable operation of all mechanical products. In these instructions we recommend and describe effective procedures you should follow when installing Volvo Penta sterndrive products. Some of these methods require the use of tools especially designed for the purpose. These tools should be used whenever recommended. Follow these steps in the order listed to perform a complete installation of a Volvo Penta engine assembly:

Prepare for Installation

Read installation instructions completely, and collect all tools, instruments, and parts needed for the job before you start work.

Special tools required:

Volvo Penta Solo Drive Unit Cart, P/N 9990001 Lifting Eye ( in.- 13 threads) Grease Gun Alignment Tool, P/N 3851083 Universal Handle, P/N 3850609 Prop Nut Tool Kit, P/N 3855516 Sealants and Lubricants as Required: Volvo Penta Water Resistant Grease, P/N 828250 Volvo Penta DuraPlus GL 5 Synthetic Gear Lube, P/N qt. 3851128, gal. 3851129, 5 gal. 3851133 Volvo Penta Trim/Tilt and Power Steering Fluid, P/N 3851039 White Sealing Compound For Drives P/N 1141570

44

Sterndrive
Note! All sterndrive system components must be matched for
either single or dual engine installations. The engine, transom shield, and drive unit model numbers must correspond according to the separate sheet shipped with the drive unit. See pictures found on the sheet shipped with the drive unit for the model number locations. Failure to properly match the engine and drive unit will result in poor boat performance, and risk damage to the engine and drive because of incorrect drive gear ratio. 1. Support trim/tilt hydraulic cylinders before cutting tie straps to prevent damage to hydraulic lines. Remove each tie strap and carefully lower hydraulic cylinders. Remove and retain retaining nuts . Remove and discard shipping board . Remove and retain e-clip, washer, and pivot rod.

A D C E

47543

F F
2. Remove and discard flat shipping washers from transom shield studs.

47544

3. Remove and retain oil level dipstick and gasket.

34070

4. Fully thread lifting eye into oil indicator hole.

34069

45

Sterndrive

5. Use a suitable hoist to remove drive unit from shipping carton. Remove and discard protective cardboard support from driveshaft.

34068

6. Remove plastic bag from greased drive shaft. Check contents of the drive unit hardware kit. The four lock nuts G and two trim/tilt pin covers H are for attachment of the drive unit.

34067

H G

47545

A
7. Remove the drive unit model and serial number identification plate . Remove and discard protective cardboard from propeller shaft, and inspect propeller mounting hardware.

34066

46

Sterndrive

Mechanical steering models only: A trim tab for the drive unit has been shipped with the engine. This trim tab must be used with a mechanical steering engine.

WARNING Failure to use the trim tab could result loss of

control of the boat and possible injury to the operator and occupants.

C
34130B

9. Remove the plastic plug at the rear of the anti-ventilation plate. Install trim tab and secure with screw Position the trim tab parallel to the centerline of the propshaft as a preliminary adjustment. Tighten the screw to 14-16 ft. lb. (19-22 Nm).

10. The boat transom design may require the transfer of the drive unit from a hoist onto a drive unit cart.

34065

11. Remove lifting eye bolt from upper housing. Check oil level with dipstick and, if required, fill to indicator plug mark with Volvo Penta DuraPlus GL 5 Synthetic Gear Lube.

34064

12. Reinstall oil level dipstick and gasket. Tighten oil level dipstick securely.

34063

47

Sterndrive
13. Inspect the tapered end of the bearing housing to ensure it is free of nicks and dents. Apply a light coat of Volvo Penta water resistant grease, P/N 828250-1, to tapered end E of bearing housing.

34062

14. Inspect molded rubber seal ring for proper fit in its groove. Inspect and lightly lubricate U-joint bellows lip with Volvo Penta water resistant grease, P/N 828250-1.

F
47546

15. Slide alignment tool P/N 3851083-0 through gimbal bearing. The alignment tool must slide through the gimbal bearing and into engine coupler with ease. If the alignment tool binds going into engine coupler, the front engine mount(s) must be adjusted either up or down, as required, until alignment tool slides in and out of engine coupler with ease.

H
47547

J
16. Remove and retain the three rear cover screws and cover.

34059

48

Sterndrive
17. Shift drive unit into gear by rotating the eccentric piston arm either up or down.

47135A

18. Apply white sealing compound for drives or water resistant grease, P/N 828250-1, to the six studs.

47548

Installing Drive Unit

B A

1. Slide driveshaft through gimbal bearing. Slide universal coupler into U-joint bellows.

34055

2. To align the driveshaft splines, rotate propeller shaft(s) until the driveshaft splines engage the flywheel coupler. Use a soft jaw pliers to rotate the propeller shaft(s) if it is difficult to turn by hand.

DR2023

49

Sterndrive

6
3. Slide drive unit onto the six studs until it is completely seated against the pivot housing. Install six lock nuts (three on each side).

3 1

4
4. Tighten the nuts in two steps. Use 3/8 in. drive, 5/8 in. swivel socket to tighten nuts to an initial setting of 25 ft. lb. (34 Nm). Start with the center nut and work in a crisscross pattern to secure the drive unit to the pivot housing. Use the same crisscross pattern to tighten all six lock nuts to a final setting of 50 ft. lb. (68 Nm).

5
DR1074

C
47129A

5. If a drive unit cart has been used, remove it at this time for installation of the trim/tilt cylinders. Apply Volvo Penta water resistant grease, P/N 828250-1, to the trim/tilt pivot pin.

D
47549

6. Align trim/tilt cylinder end with upper housing boss. Slide trim/ tilt pivot pin through trim/tilt cylinder and upper housing.

D
47550

50

Sterndrive

E F
47551

7. Align and slide pivot pin through trim/tilt cylinder end. Install flat washer and e-clip.

Note!

The e-clip must be installed on the inner groove of the pivot pin. The washer must be installed inside the e-clip.

8. Install rod end covers onto pivot pin.

G
47552

Check and Adjust Trim Sending Unit

1. Push trim/tilt switch to the down position. Drive unit must be in a full trim-down position before adjusting the trim sending unit. 2. Loosen trim gauge sending unit screws on starboard side of gimbal ring.

18440

3. Rotate trim gauge sending unit as required to achieve a full down reading on the trim gauge. 4. Tighten trim gauge sending unit screws to 24 in. lb. (2.7 Nm).

18439

51

Sterndrive
Shift Cable Installation
1. If the remote control shift and throttle cables are installed in the remote controls, proceed to Check Remote Control Shift Cable Stroke. 2. If the remote control shift cable has not been installed, the following procedure will permit you to order the correct length remote control shift cables. 3. Measure the proposed route of the remote control shift cable. All bends must have a radius greater than 6 inches (15.2 cm).

Remote control shift cable

Add
D

plus 20 in. (50.8 cm), round up to next cable length.

CAUTION When removing shift and throttle cables from the

packing box, DO NOT bend the cables tighter than a 6 inch radius.

Check installation of shift cable

All Models:
Shift cable should PULL for forward gear on right-hand rotation SX drives and DP-S applications.

Twin Installations, SX Models Only:

Shift cable should PUSH for forward gear for left-hand rotation propeller applications. This change is accomplished at the remote control.

E
DR4939A

CAUTION Check installation of throttle cable. Throttle cable should PULL to open and PUSH to close.
Check Remote Control Shift Cable Stroke
1. Move the remote control handle to the Wide Open Throttle (WOT) position in the direction needed to retract the shift cable. Pull out the cable core wire to remove end play. Mark the cable core wire at the end of the casing.

36560

2. Return remote control shift handle to the neutral detent position. Measure and record the distance between mark and end of casing.

D
INCHES

36561

3. Mark cable core wire at end of casing with control in the neutral detent position.

36562

52

Sterndrive

E
INCHES

4. Move the remote control handle to the Wide Open Throttle (WOT) position in the direction needed to extend the shift cable. Push in on cable core wire to remove end play. Measure and record the distance between mark and end of casing.
1 2 3

36563

The distance between forward and neutral must be no less than 1 in. (31.8 mm) and no greater than 13/8 in. (35.0 mm). The distance between neutral and reverse must be no less than 1 in. (31.8 mm) and no greater than 13/8 in. (35.0 mm).

Note! If your measurements are not within these specifications,

check your remote control installation instructions. Make sure the cables are attached correctly inside the control box before continuing.

CAUTION All control boxes must meet these minimum and

maximum specifications in order for the shift system to function properly.

Shift Cable Installation

G
Note! Remote control shift and throttle cables must be SAE type
34045

cables. If shift cable was previously installed in the transom shield, skip to step 5. 1. If the throttle cable is attached to the throttle arm and anchor block, remove it from both. The throttle cable must be disconnected from the throttle arm prior to shift cable installation and adjustment to prevent loading the control box and adversely affecting shift adjustments. 2. Note position of small seal F and large seal G of the shift cable. Remove and retain jam nut, small seal, and large seal from the shift cable. 3. Retract inner core wire of shift cable. Apply a light coat of Volvo Penta water resistant grease, P/N 828250-1, to the end of the remote control shift cable casing. Slide shift cable through transom sleeve and connector assembly until it appears on the outside of the transom.

34044

53

4. For ease of installation of shift cable, turn drive unit to port. Reinstall the large seal G and small seal F onto the shift cable in the same position as noted in step 2.

G F
47553

5. Loosen cable anchor clamp

and slide to starboard.

A
47554

6. Slide shift cable through pivot housing and drive unit. Slide anchor clamp in, engaging the shift cable anchor groove. Tighten anchor clamp screw securely.

47555

7. Rotate eccentric piston arm

to extend bellcrank.

B
47131

8. Remove cotter pin, flat washer, and cube from bellcrank

C
47132

9. Thread cube halfway onto remote control cable end. Rotate shift lever back to neutral detent position, then move remote control handle to its neutral detent position. Turn cube IN or OUT until it aligns with center of bellcrank slot

47130A

10. Install flat washer

and cotter pin.

E
47133

G F
47134A

11. Bend prongs of cotter pin F . Install jam nut G and tighten securely against cube to keep cable from turning in cube.

Sterndrive
Shift System Test
Shift unit into forward and reverse gear several times. Ensure full forward and reverse gear engagement occurs. Boat must move in direction of selected gear (i.e., with control handle in forward, boat moves forward). Refer to the remote control manufacturers service manual to correct any deficiencies before delivery of boat.

Note! When shifting from neutral into forward and reverse gear, the movement of remote control handle required to obtain gear engagement should be approximately equal in both directions. If not, the shift cable trunnion has to be readjusted to obtain a centered shift stroke.

Start-in-Neutral-Only Test
CAUTION Operate bilge blower as recommended by boat
manufacturer before starting engine, to prevent explosion. Open engine cover or hatch before starting engine if the boat is not equipped with a blower. Leave it open until after engine has started.
47557

WARNING The remote control should be designed to allow

starting in NEUTRAL only. If control handle is in an in gear position, engine should not crank. Test to make certain engine will not crank in forward or reverse gear positions, and will crank only when control handle is in neutral position. 12. After shift system tests are performed, and all adjustments are made, reinstall the rear cover using the original screws.

E D A

F
DR2498

Propeller Installation
SX Models
A propeller was not shipped with your sterndrive. The correct propeller must be selected to match engine and boat as a unit to give the best engine life, fuel economy, and performance. The boat manufacturer has performed tests to determine the optimum propeller for each boat and engine combination. Consult the boat manufacturer for their recommendations on the correct propeller to initially install or refer to the propeller selection charts found in the Propeller section of the Drive Unit/Transom Shield service manual. 1. Coat the full length of the propeller shaft with Volvo Penta water resistant grease, P/N 828250-1. 2. Place thrust bushing on propeller shaft with inner taper toward gearcase to match the taper on propeller shaft. 3. Slide propeller onto propeller shaft, align splines, and push propeller onto thrust bushing until splines are exposed. 4. Place thrust washer on propeller shaft splines. 5. Shift the remote control into REVERSE gear to lock the propeller shaft. 6. Install and tighten the propeller nut to 70-80 ft. IT (95-108 Nm). 56
6602

6604B

Sterndrive
7. Index keeper on propeller nut until aligned with cotter pin hole 8. Install cotter pin and bend prongs to secure (use new cotter pin if necessary). 9. Shift the remote control into NEUTRAL. Propeller should turn freely. The propeller spacer, nut, keeper, and cotter pin must be installed as shown.

CAUTION Failure to install all components could result in

loss of the propeller when boat is operated in REVERSE.
6598

DP-S Models
Propellers were not shipped with your sterndrive. The correct propellers must be selected to match engine and boat combination to give the best engine life, fuel economy, and performance. The boat manufacturer has performed tests to determine the optimum propellers for each boat and engine combination. Consult the boat manufacturer for propeller recommendations, or refer to the Power and Propeller Performance Charts, P/N 7797205, published by Volvo Penta. Tools for removing and installing the propellers are contained in Volvo Pentas propeller tool kit, P/N 3855516-5.

A VOLVO PENT

GR990995

CAUTION D-series aluminum propeller sets used on

Duoprop applications are not recommended for use on boat and engine combinations capable of speeds in excess of 40 MPH. F-series stainless steel propeller sets should be used in these applications. If you use D-series aluminum propeller sets, you must also use an in-trim limiter kit, P/N 3857598-1. 1. Coat the full length of both propeller shafts with Volvo Penta water resistant grease, P/N 828250-1. 2. Place the remote control in the FORWARD gear position to lock the propeller shafts. Install the front propeller. 3. Install the front propeller nut and tighten to 45 ft. lb. (60 Nm). Use propeller tool, P/N 3851615-9.

GR990996

CAUTION Be sure the chamfered edge of the propeller nut

is facing forward. Failure to install the propeller nut correctly could result in a propeller coming loose and damage to the lower unit and/or the propeller.

GR990998

57

Sterndrive
4. Place the remote control in the REVERSE gear position to lock the propeller shafts. 5. Install the rear propeller.
VO LV O PE

6. Install the rear propeller nut and tighten to 50 ft. lb. (70 Nm). Use a propeller tool, P/N 3851616-7.

NT A DU OP RO P

CAUTION Failure to install the propellers as indicated could

result in the loss of the rear propeller and damage to the lower unit. 7. Shift the remote control into NEUTRAL. Both propellers should turn freely.
GR990991

Pre-delivery Checklist
1. Install boat drain plug. 2. Install and tighten all water drain petcocks. Install exhaust manifold end cap and clamps. Tighten clamps securely. Check and tighten all hose clamps. 3. Check all battery and electrical connections for tightness.
GR990999

4. Check engine, power steering, and drive unit oil levels. 5. Fill gas tank for initial testing. 6.

DANGER Check all fuel line and hose connections for

fuel leaks.

7. Check operation of gauges, bilge pump and blower. 8. Check operation of anchor light, running lights and dash lights. 9. Check trim/tilt reservoir oil level. Level should be between the MIN and MAX marks on the reservoir. Check trim/tilt operation.
GR990989

58

Sterndrive

A C

DR4960

Static Water Line Test

CAUTION The static water line height must be tested before the engine is started for the first time. This will prevent the ingestion of water into the engine and resultant damage. Determine if the engine meets the static water line height requirements after the engine and drive unit have been installed in the boat. The boat must be in water with its recommended load capacity distributed aboard.1. Place a level on top of transom, measure from bottom of level to top of elbow and record measurement.
2. Measure from bottom of level to static water line and record measurement. 3. Subtract measurement from measurement and record result. Measurement should not be less than 14 in. (35.6 cm). 4. When the engine installation does not meet these specifications, contact the Volvo Penta service department for information on high rise extension kits. Make sure this is corrected before the engine is started for the first time.

Note! An installation that permits water to enter the engine through the exhaust manifold(s) will not be
covered by warranty, unless damage is due to defective part(s).

59

Sterndrive

On-Water Tests and Adjustments

Launch boat for water test of static water line, engine, steering, trim/tilt, correct propeller, and the shift system.

Check Engine Operation

1. The fuel system may have to be primed prior to starting. Shift into neutral. Turn key switch and crank engine for approximately 10 seconds. Return key switch to off position, then repeat the cycle until engine starts. Do not crank the engine longer than 10 seconds. This will prevent damage to the starter motor.

CAUTION The electric fuel pump used on some models

cannot be run dry for longer than 20 seconds. Running the pump for longer time periods will result in pump failure. 2. Check the oil pressure gauge. The gauge should indicate engine oil pressure within seconds of the engine starting. Shut the engine down if no or low pressure is indicated. 3.

WARNING Check the fuel system for leaks and correct

as necessary.

CAUTION Tie boat securely to dock to prevent forward or backward motion.

4. Check the engine water temperature gauge. The water temperature should be within an acceptable heat range, as follows: Engine Acceptable heat range

3.0 GS . . . . . . . . . . . . . . . . . . . 157-175F (70-80C) 4.3 GL, 4.3 Gi . . . . . . . . . . . . . 157-175F (70-80C) 5.0 GL . . . . . . . . . . . . . . . . . . . 157-175F (70-80C) 5.7 GSi . . . . . . . . . . . . . . . . . . 157-175F (70-80C) 7.4Gi, 7.4GSi . . . . . . . . . . . . . . 140-150F (60-66C) 5. Check the voltmeter. The voltmeter should indicate that charging and electrical systems are operating properly. 6. Check the steering operation. The steering wheel must have equal number of turns to port and starboard from centered position. Bow of boat must move in direction steering wheel is turned. Check power steering pump reservoir after engine is shut down for proper fluid level. 7. Check trim/tilt system and trim gauge operation through full up and down tilt range. 8. Check for exhaust system water/exhaust leaks. 9. Check operation of all boat accessories.

60

Sterndrive

Tie Bar Adjustment

A toe-in condition should be created on deep V-shaped boat hulls for improved performance and efficiency. A commonly used toe-in condition is one in which D dimension will be 1/4 in. to 3/8 in. (6.35 to 9.53 mm) less than dimension E . Remove the steering tie bar from the port tiller arm. Loosen the port jam nut F of the tie bar. Turn jam nut out 1/16 to 3/32 in. (1.59 to 2.38 mm) G as required, and screw in port steering tie bar end H . Retighten the jam nut F.

E
DR3026

CAUTION Threads of the port tie bar must be visible through

the inspection hole I to insure adequate thread engagement between the rod and tube. Failure to ensure proper threads engagement could result in component failure resulting in possible loss of steering control.

Duoprop Drive Unit Twin Installations:

The drive unit must be adjusted so operation is free from Ventilation. To adjust, measure the distance between the center line of the two transom shields. Adjust tie bar so the distance between the center of the anti-ventilation plate is equal to distance. Hold the drive units when measuring.

F
21085A

Trim Tab Adjustment

Models With Power Steering
Trim tab adjustment is not required on power steering installations.

Models Without Power Steering

CAUTION Improper trim tab adjustment can cause difficult steering.
An adjustable trim tab is provided to compensate for propeller torque and allows you to balance steering effort in either direction. Test the boat to see if further adjustment is needed. With a firm grip on the steering wheel and the weight in the boat evenly distributed, run the boat at full throttle in a straight line. Do this in an area where current and wind will not be a factor. Turn the steering wheel to port and starboard. Determine which direction requires the least amount of steering effort.

CAUTION When adjusting the trim tab, stop the engine and raise the drive unit out of the water.
If less steering effort was required in a port turn, loosen the trim tab screw and move the rear edge of the trim tab slightly to the port. Tighten screw. If less steering effort was required in a starboard turn, loosen trim tab screw and move the rear edge of the trim tab slightly to the starboard. Tighten screw.

Repeat the above procedure until steering effort is equal in both directions. After adjustment is complete, tighten the trim tab screw ft. lb. (19-22 Nm).
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Publ. No. 7797282

Volvo Penta of the Americas

1300 Volvo Penta Drive Chesapeake Virginia 23320

1999, Volvo Penta of the Americas, Inc. All rights reserved. Printed in USA.