Page 1 Installation Aquamatic SX, DPS 1(1) Inboard...
Page 3: Table Of Contents
Aquamatic drive ..................63 Inboard Applications ................108 Cooling System ..................140 Fuel System ..................141 Electrical System ................. 155 Fire Extinguishing System ..............167 Launching and Sea Trial ................ 169 Alphabetical index .................. 179 47700829 04-2013 © AB VOLVO PENTA...
Page 4: Safety Information
Safety Information This installation manual contains information required Only start the engine in well-ventilated areas. for the correct installation of your Volvo Penta prod- Remember that exhaust fumes are toxic and danger- uct. Check that you have the correct manual.
Page 5 Risk of injury. start the engine (risk for sparks) and do not lean over the batteries. 47700829 04-2013 © AB VOLVO PENTA...
Page 6 Safety Information Make sure that the positive (+) and negative (–) Always use fuels recommended by Volvo Penta. battery cables are correctly connected to the corre- Refer to the Operator's Manual. Poor quality fuel may sponding battery terminals. Wrong connection may damage the engine.
Page 7: General Information
0,869 knop 1,1508 Temperature Celsius Fahrenheit °F=9/5 x °C Fahrenheit Celsius °C=5/9 x (°F– 1) All hp figures stated in the catalogue are metric. 2) All hp figures stated in the catalogue are metric. 47700829 04-2013 © AB VOLVO PENTA...
Page 8: Installation Tools And Documentation
Installation Tools and Documentation Publications Drawings Drawings in respect of the current program of leisure and professional applications are available at: http://www.volvopenta.com Printed material • Volvo Penta accessories & maintenance parts Service Manuals • • Operators' Manuals • Sales guide Posters •...
Page 9 Concerning templates for controls, keypads, instrument panels etc, refer to their installation instruc- tions. P0008120 Adapter kit, Transom VP part # 3889814. Adapter for converting older type transom shields (type 290) to the current model. 47700829 04-2013 © AB VOLVO PENTA...
Page 10: Special Tools
Engine alignment on engine with 3851083 Alignment tool shield installation P0008217 P0007804 3855516 Rotation tool 3588569 Drill jig Propeller nut tool kit for DPS Laying out engine bed and for- sterndrives ward engine mounts 47700829 04-2013 © AB VOLVO PENTA...
Page 11 Measuring exhaust gas temper- Measuring pressure, fuel lines ature. Used together with 88890074 Multimeter 9996065 Pressure gauge 9996666 Nipple 9996398 Pressure gauge Measuring exhaust back pres- Exhaust back pressure Measuring pressure, fuel lines sure 47700829 04-2013 © AB VOLVO PENTA...
Page 12: Design Concept Of Propulsion Systems
EVC. Max trim limits for sterndrives at 13° transom angle. Max tilt (B) 52° 52° Beach trim (C) 30° 30° Max trim (D) 12° 6° Min. trim (E). -5° -5° P0008123 Horizontal plane 47700829 04-2013 © AB VOLVO PENTA...
Page 13: Reverse Gear
Propeller shaft angle is straight at the same angle as the crankshaft. Engine and reverse gear form a single unit. Propeller thrust is taken up by a bearing in the reverse gear. 47700829 04-2013 © AB VOLVO PENTA...
Page 14: Engine Characteristics
10 kPa (1.45 psi). If all engine man- ufacturers used the same test procedure it would be simpler for boat builders to compare products from dif- ferent manufacturers. 47700829 04-2013 © AB VOLVO PENTA...
Page 15 Considering this, it is important to remember that boats made of GRP absorb water when they are in the water, 47700829 04-2013 © AB VOLVO PENTA...
Page 16 When the prototype and first production boat are built, Engine power, kW the boat builder and a representative from Volvo Penta carry out a full load trial with the boat under conditions similar to those the boat will meet with the customer.
Page 17 A Engine power may vary within international power norm tolerances. Propeller precision B Calculated hull resistance and displacement tolerance ±3 may vary within certain limits. C Propeller manufacturing tolerances generally influence engine rpm in that propeller power var- ies. 47700829 04-2013 © AB VOLVO PENTA...
Page 18: Arrangement And Planning
E Approximately 1 x shaft diameter F Shaft angle. If possible, avoid angles in excess of 12°. Dimension (A) may never be less than 50 mm (2"). Classification authority requirements must be followed when the boat is classified. 47700829 04-2013 © AB VOLVO PENTA...
Page 19 Low speed planing boats generally low revolu- tions 1.92:1–2.48:1 1,92:1–2,48:1 Semi-planing to planing boats, patrol boats 16–30 knots (D3-110) Sport fishing boats 2.03–2.48 (D3-150) Pleasure boats 1,92:1–2,48:1 Planing boats 25–40 knots Patrol boats Sport fishing boats Pleasure boats 47700829 04-2013 © AB VOLVO PENTA...
Page 20: Propeller Shafts
There must also be a certain safety margin. The max- imum distance between bearings has great influence on shaft dimension calculations. Refer to the graph below: check the Volvo Penta com- puter program or ask the shaft supplier for advice to determine shaft dimensions and bearing distances.
Page 21 ±0.008) HS63IV 133 (5.25) 108 ±0.1 63.5 H8 9.5 (0.37) 6.0 (0.23) 4 x 11.5 (0.45) ø 56 (4.25 (2.5 H0.3) ±0.004) ZF45-1 152.4 120.6 76.2 14.2 6 (0.23) 6 x 13.2 (0.52) (0.56) 47700829 04-2013 © AB VOLVO PENTA...
Page 22 P0005932 When test driving a new installation it is important to check that water lubrication functions satisfactorily at Shaft sealing full speed. Make sure that the pipes provide sufficient Intake pipe water flow. 47700829 04-2013 © AB VOLVO PENTA...
Page 23 Slide the propeller shaft into place and align the shaft and stern bearing with the reverse gear output shaft (reverse gear flange). To prevent the shaft from bend- ing in the stern tube, center the shaft as follows: P0005935 47700829 04-2013 © AB VOLVO PENTA...
Page 24 If the stern tube is to be bolted into the stern, the bear- ing flange contact surface must first be ground flat. Brush on sealing compound e.g. silicone rubber, and tighten the bearing retaining bolts. NOTICE! Check the alignment after gluing. 47700829 04-2013 © AB VOLVO PENTA...
Page 25 1 x propeller shaft diameter (X). P0013029 There must be 2 mm (0.08") play between the shaft forward end and the reverse gear flange (flexible cou- pling). P0005939 47700829 04-2013 © AB VOLVO PENTA...
Page 26: Engine Placement
Standard Flywheel Flywheel Transverse lubrication downward upward Max inclina- system Max inclina- Max inclina- tion tion tion Under way 20° 10° 20° Static 5° 0° 0° P0005830 Flywheel downward Flywheel upward WL = Waterline 47700829 04-2013 © AB VOLVO PENTA...
Page 27 Use the installation drawings to calculate a suitable distance. Generally speaking the minimum recommended dis- tance between the engine centerlines (A) is 800 mm (31.5") with conventional steering and 900 mm (35.4") for electronic steering. P0008289 47700829 04-2013 © AB VOLVO PENTA...
Page 28: Engine Room
• Oil filter change • Fuel filter change • Air filter change • Drive belt inspections • Drive belt changes • Removing the valve cover Impeller change, seawater pump • • Water filter, cleaning 47700829 04-2013 © AB VOLVO PENTA...
Page 29 Removal of charge air cooler • Removal of oil cooler • Removal or exchange of electrical components • Removal of flywheel and vibration dampers • Removal or exchange of steering equipment • Removal of engine P0008124 47700829 04-2013 © AB VOLVO PENTA...
Page 30: Engine Room Ventilation
Ventilation must also be suitably adapted if crew mem- bers will be present in the engine compartment. NOTICE! Current national safety regulations and leg- islation must be followed. Each classification society has its own rules that must be followed when so required. 47700829 04-2013 © AB VOLVO PENTA...
Page 31 However, power loss is not important below approx 500 m (1640 ft) above sea level. At altitudes in excess of 500 m (1 640 ft.) above sea level, power loss is around 2% per 100 m (328 ft.). 47700829 04-2013 © AB VOLVO PENTA...
Page 32 NOTICE! The total inlet cross-sectional area can be calculated using the formula: Total inlet cross-sectional area = engine air consump- tion + engine compartment ventilation 47700829 04-2013 © AB VOLVO PENTA...
Page 33 NOTICE! Fan hose connections for diesel engines must be located as high up in the engine compartment as possible to carry away hot air, while as low as pos- sible for gasoline engines to carry away fumes. 47700829 04-2013 © AB VOLVO PENTA...
Page 34: Engine Temperature
70 °C. However, the starter motor and alternator have their given locations. Engine compartment pressure Volvo Penta recommends that the negative pressure in the engine compartment does not fall below 0.5 kPa at full speed. A slight negative pressure in the engine...
Page 35: Engine Compartment Ventilation
1 in regard to bends and duct length. Outdoor temperature is assumed to be +30 °C. Cor- rection factors as described in table 2 must be used when appropriate. Correction factor Ambient temperature Correction °C factor 47700829 04-2013 © AB VOLVO PENTA...
Page 36 . This gives a diameter of 184 mm for one engine. 3 Capacity, extraction fan: 0.07 × 162 (kW) = 11.3 /min. 4 NOTICE! The figures must be multiplied by 2 as this is a twin installation. 47700829 04-2013 © AB VOLVO PENTA...
Page 37 This gives 170 × 0.7 × 1.41 = 168 cm . This corre- sponds to a duct diameter of 146 mm for each inlet and outlet. 4 Capacity, extraction fan: 0.07 × 103 (kW) = 7.2 /min. 47700829 04-2013 © AB VOLVO PENTA...
Page 38 Inlet duct, engine compartment radius is double the diameter. Obstacles or constric- Ventilation tions must always be avoided. Water trap The ducts must be cut obliquely at the ends to provide Extraction fan best flow. 47700829 04-2013 © AB VOLVO PENTA...
Page 39 Remember to build the engine compartment as spaciously as possible to facilitate engine service. P0004734 47700829 04-2013 © AB VOLVO PENTA...
Page 40: Sound Absorption
Screen off the entire bulkhead down to the hull, but leave a little gap so that bilge water does not force its way into the insulation material. P0004735 Engine compartment noise baffles 47700829 04-2013 © AB VOLVO PENTA...
Page 41 Also make sure that all covers are properly insulated. Min. 180 mm (7”) Min. 200 mm (8”) P0004738 Check cover sealing P0006333 47700829 04-2013 © AB VOLVO PENTA...
Page 42 When electrical cables are run through a bulkhead, it is advantageous to run them through a conduit or grommet that can be sealed properly. This also pro- tects the cable against wear. Bulkhead bushings 47700829 04-2013 © AB VOLVO PENTA...
Page 43 PVC pipe (installation pipe) built into the hull. Any gaps between the pipes and the cables can be sealed with insulating material or sealing compound. P0006334 Fuel hose protected by a grommet 47700829 04-2013 © AB VOLVO PENTA...
Page 44: Electrochemical Corrosion
The depth of attack then becomes basically equal across the entire surface. This commonly occurs on steel and bronze. P0011417 47700829 04-2013 © AB VOLVO PENTA...
Page 45 Aluminum can be subject to a certain amount of gen- eral corrosion in rapidly flowing water, but not in sta- tionary water. 47700829 04-2013 © AB VOLVO PENTA...
Page 46 Deposit corrosion is closely related to crevice corro- p0011420 sion. It takes place under deposits and marine fouling such as barnacles. 47700829 04-2013 © AB VOLVO PENTA...
Page 47: Galvanic Corrosion
This coating is not face. In fresh water, there will be more local attack present in the active state. close to the point of contact. ** Still water. 47700829 04-2013 © AB VOLVO PENTA...
Page 48: Stray Current Corrosion
The AC corrosion rate for aluminum is 30% of the rate for DC. The cor- responding rates for steel, copper and zinc are much lower, at 1 %. Please refer to the figure to the left. 47700829 04-2013 © AB VOLVO PENTA...
Page 49: Corrosion Protection
- Carefully designed electrical system. - Recommendations to minimize external interfer- ence. Recommendations from Volvo Penta and anti fouling manufacturers must be followed. In addition, the mate- rial must be resistant to the alkali that is formed on cathodically protected surfaces.
Page 50 Please note that magnesium anodes give overprotection to aluminum in seawater. There is no risk of overprotection of alu- minium if zinc or aluminum anodes are used for pro- tection. 47700829 04-2013 © AB VOLVO PENTA...
Page 51 1/3 has been used up by corrosion. All anodes do not share the same quality! Always use anodes produced by Volvo Penta since they have been tested to ensure maximum protection on stern drives and props.
Page 52 A GFCI located on the boat side of the isolation trans- former safeguards ground fault protection in the boat. This is supplement to ABYC E-11 that ensures a higher level of protection against electric shock. 47700829 04-2013 © AB VOLVO PENTA...
Page 53 In order to avoid galvanic corrosion to underwater components such as hull penetrations, swim ladders etc., it is important that they be protected. Volvo Penta recommends that all components be connected to a protection anode installed on the transom. Trim planes may have their own protection.
Page 54 Commission and the American Boat and Yacht Coun- cil. In particular, the publications IEC 60092-507:2000 Electrical installation in ships Part 507: Pleasure craft, and ABYC Standards and guidelines H-33 and E-4 may prove helpful. 47700829 04-2013 © AB VOLVO PENTA...
Page 55: Bottom Painting
Arrangement and Planning, Electrochemical Corrosion ACPS Volvo Penta ACPS Active Corrosion Protection pro- tects the sterndrive against galvanic corrosion by con- trolling an electric current that is monitored by a refer- ence sensor. ACPS acts as a secondary protection, i.e. as a com- plement to the existing sterndrive and transom shield anode protection.
Page 56 19 Encapsulated single-phase 1:1 isolated transformer with metal shield 20 Main switch, shore power, with overvoltage protection 21 Power supply (isolated electrically from boat) 22 Connector, shore power cable 23 Shore supply cable 24 Shore connection 47700829 04-2013 © AB VOLVO PENTA...
Page 57 22 Encapsulated single-phase 1:1 isolated transformer with metal shield 23 Main switch, shore power, with overvoltage protection 24 Power supply (isolated electrically from boat) 25 Connector, shore power cable 26 Shore power cable 27 Shore connection 47700829 04-2013 © AB VOLVO PENTA...
Page 58: Shore Power
Shore power In regard to personal safety and equipment care, When shore power (120/230 V) is connected, shore Volvo Penta provides the following recommendations power ground protection must not be connected to the for the installation of AC shore power: engine or any other grounding point in the boat.
Page 59 Work on the low voltage circuits in the boats should be done by a person with electrical training or knowledge. Installation or work on land current equipment must only be done by a competent electrician, in accordance with local regulations for mains electricity. 47700829 04-2013 © AB VOLVO PENTA...
Page 60 In this system an electrical current protects sterndrives and transom shields from galvanic corrosion. Propellers Volvo Penta stainless steel propellers installed on DPS sterndrives are electrically insulated from the drive and will therefore not cause any anode consumption. 47700829 04-2013 © AB VOLVO PENTA...
Page 61 The rough guide below indicates what these readings means in practical terms: • 10.000 Ohm up to open circuit A next to perfect cir- cuit, no problems. • 5.000 Ohm – There is a small leak. 47700829 04-2013 © AB VOLVO PENTA...
Page 62 Trace the circuit until the fault is found, and repair it. P0004775 Charging Oil pressure 47700829 04-2013 © AB VOLVO PENTA...
Page 63: Measurement Theory
88890074 Multimeter 21504294 Reference electrode Measuring galvanic current and stray current in water Volvo Penta has developed a method for measuring 21504294 Reference electrode galvanic current and stray current in water using a ref- erence electrode. 21504294 Reference electrode (Ag/AgCl) is con- nected to 88890074 Multimeter.
Page 64 VHF radio or other equipment fitted with an incorrectly connected ground cable. The cause may also be that the anodes are emitting excessive protection current, e.g. magnesium anodes in saltwater. 47700829 04-2013 © AB VOLVO PENTA...
Page 65: Installation
Follow mounting instructions in the extension kit. Cal- culate the position of the hole for the transom shield when an extension is installed. Use the recommended X measurement and add the length of the extension (H), 25.4 mm (1”). P0008126 47700829 04-2013 © AB VOLVO PENTA...
Page 66 Exactly the same radius must be used for both arcs for the transom upper center point to be positioned precisely. Repeat the procedure to mark out the lower transom center point; if necessary use a dif- ferent radius. P0007478 47700829 04-2013 © AB VOLVO PENTA...
Page 67 (X dimension) SX = 20 mm (0.79”) can only be determined by testing. The recommended Volvo Penta X dimension must be used as a starting DPS = 20 mm (0.79”) point. Volvo Penta recommends that the following routine be...
Page 68: Single Installation
SX, DPS Sterndrives (14.17) (14.09) (14.01) (13.97) (13.93) (13.85) (13.81) mm (") Control dimension Y 95 (3.74) 93 (3.66) 91 (3.58) 90 (3.54) 89 (3.50) 87 (3.43) 86 (3.39) SX, DPS Sterndrives mm (") 47700829 04-2013 © AB VOLVO PENTA...
Page 69: Twin Installation
P0007487 crankshaft centerline (X dimension). NOTICE! The check dimension Y is used to verify the right height after shield installation. The dimension can vary depending on the bottom radius. α° P0008128 47700829 04-2013 © AB VOLVO PENTA...
Page 70 Keels, strakes, ladders, etc. may not be within distance B from the transom. P0007450 Single installation Twin installation Critical areas may overlap one another depending on the distance between the engines. P0007451 Twin installation 47700829 04-2013 © AB VOLVO PENTA...
Page 71 (0.51") bolts, flat washers and nuts supplied with the drill fixture. Screw a woodscrew into one of the small holes to prevent the fixture from rotating. 4. Mark out the shield hole on the transom using a pen. P0008129 47700829 04-2013 © AB VOLVO PENTA...
Page 72 If the cut is made too far inside the line the shield will be difficult to install. The shield stud installation holes will be weakened if the cut is made too far out. P0008132 47700829 04-2013 © AB VOLVO PENTA...
Page 73 (drill rod). Drill two 45 mm (1.77") holes with the aid of the guide holes. 9. Remove the template. 10. Cut out the hole using the power jigsaw. Hold the saw perpendicular to the transom. P0008211 47700829 04-2013 © AB VOLVO PENTA...
Page 74 3. Saw or file a channel in the inside edge of the cut- out to drain trapped water to bilge. P0008213 The arrow points inboard 4. Seal the transom opening with a suitable sealant to prevent water from soaking into and damaging the transom. P0008214 47700829 04-2013 © AB VOLVO PENTA...
Page 75 1. Make sure the trim cylinders are attached to a wood panel or similar. 2. Apply a thin coat of Volvo Penta waterproof grease (1), 828250, to the inner transom plate guide sleeve, transom shield studs. bolts and exhaust seal.
Page 76 Clamp it at least 350 mm (13.8") (A) above the crankshaft center line, regardless of whether it is to be used or not. 47700829 04-2013 © AB VOLVO PENTA...
Page 77: Engine Foundation
For further information refer to Service Bulletin 08-5-8. 72,9 mm 140 0,5 mm NOTICE! Note that there must be a recess in the side (2.87”) (5.51 0.03”) of the engine bed to accommodate the exhaust pipe. 4x 6 mm (0.24”) P0008940 47700829 04-2013 © AB VOLVO PENTA...
Page 78 Use the drill bushings marked D3. Then remove the flexible drill jig. 6. Drill and then tap the holes using a thread tap. P0008222 IMPORTANT! The thread must be M10 mm (3/8" UNC). P0008223 47700829 04-2013 © AB VOLVO PENTA...
Page 79 Installation, Aquamatic drive Drawing showing the necessary recess in the engine bed to make room for the exhaust pipe. (11.81) (5.12) MIN 200 (7.9) p0017127 47700829 04-2013 © AB VOLVO PENTA...
Page 80: Engine Installation
NOTICE! All engines are supplied by Volvo Penta with- out engine oil and coolant. Check that the oil drain plug, coolant drain taps and hot water taps are screwed in and closed.
Page 81: Exhaust Outlet
Installation, Aquamatic drive Exhaust Outlet 1. Check that the large O-ring is in place on the transom shield. 2. Install the exhaust pipe and tighten the bolts. Tightening torque: 30 Nm (22 lbf.ft). P0008226 47700829 04-2013 © AB VOLVO PENTA...
Page 82: Raw Water System
Tighten the hose clamps. IMPORTANT! Never locate the clamp screws under the plastic sleeve. IMPORTANT! Do not tighten the clamps too hard. IMPORTANT! Do not apply any lubricant. P0008228 47700829 04-2013 © AB VOLVO PENTA...
Page 83 65 Nm (48 lbf.ft). 3. Fit the front engine mount bolts to the engine bed. Finger tighten. After installation, apply waterproof grease (VP part # 828250) to the threads protruding through the nuts. P0008231 47700829 04-2013 © AB VOLVO PENTA...
Page 84: Engine Alignment
Install the engine control unit (1) on a bulkhead with the cables facing downwards or to one side. Connect the ground cable (2) from the transom shield to the engine stay center bolt on the flywheel housing. 47700829 04-2013 © AB VOLVO PENTA...
Page 85: Cooling System
Aquamatic The complete seawater system including seawater fil- ter is supplied by Volvo Penta. The water inlet is located in the sterndrive. Volvo Penta cooling systems are designed for seawater tempera- tures of maximum 30 °C (86 °F). Water circulation from the seawater system cools: •...
Page 86: Jackshaft, Installation
Other alternatives require a TVC calculation to be made. IMPORTANT! The D3 engine may only be run with a CV shaft. For further information, refer to the Installation instruc- tions included in the jackshaft kit. 47700829 04-2013 © AB VOLVO PENTA...
Page 87: Steering System
NOTICE! Run the steering cable with as gentle bends P0008202 as possible. Minimum radius (r): 250 mm (10"). If the radius is made smaller the control function will be stiff and there is risk of it binding. 47700829 04-2013 © AB VOLVO PENTA...
Page 88 Installation, Aquamatic drive Powersteering Cylinder, Installation 1. Apply Volvo Penta waterproof grease (part # 828250) (1) to all steering cylinder linkages. 2. Install the attachment bolts (2) level with the inboard transom plate inside. 3. Brush waterproof grease onto both steering cylin- der bushes (3).
Page 89 1. Turn the wheel so that the steering piston is pushed fully out. Lubricate the full length of the steering piston with Volvo Penta waterproof grease (part # 828250) (1). 2. Hold back the attachment screw (2) on the cable sheath (3) to anchor the steering cable to the end of the steering pipe.
Page 90 Also re-route the electronic harness (3) so that it passes behind the coolant hose (2). IMPORTANT! Once the auxiliary steering cylinder is installed make sure its hydraulic unions do not touch the coolant hose bend (4) at any rudder angle. 47700829 04-2013 © AB VOLVO PENTA...
Page 91: Hydraulic Steering System
Check the oil reservoir level. Hydraulic Steering System Volvo Penta does not market a purely hydraulic steer- ing system for D3. However, a purely hydraulic steer- ing system may be recommended in boats with several helm stations.
Page 92 Cut the lines with a knife to avoid swarf and burrs. Make sure the ends are completely clean and that they are cut square. P0011623 1. Search in the “Hydraulic Steering Selection Guide” catalogue. 47700829 04-2013 © AB VOLVO PENTA...
Page 93 3 HCU 4 SCU 5 Oil cooler 6 Steering cylinder 7 Power steering oil reservoir 8 Connection panel on engine 9 Power steering pump 10 Engine start battery 11 Main switch 12 Circuit breaker 47700829 04-2013 © AB VOLVO PENTA...
Page 94 The tank must be located higher than the SCU. IMPORTANT! The tank may not be installed on the engine. NOTICE! The tank must be located higher than the steering cylinder. P0011234 47700829 04-2013 © AB VOLVO PENTA...
Page 95 Fill the system with ATF oil of type Dexron II or III while the engine is running. Volvo Penta part # 1161995 is recommended. If the system has lost a large quantity of oil during dismantling it must be vented.
Page 96 3 in Sterndrive, Installation page 97. Remove and dispose of the packaging material. P0008237 2. Remove and save the oil dipstick and the gasket. Screw a lifting eye into the dipstick hole. P0008238 47700829 04-2013 © AB VOLVO PENTA...
Page 97 6. Visually inspect the tapered part of the bearing hous- ing to ensure that it is free from hacks and dents. Apply a thin coat of Volvo Penta waterproof grease, part # 828250, to the tapered part of the bearing housing.
Page 98 Installation, Aquamatic drive 7. Check that the molded rubber seal ring fits into its groove. Inspect and lightly lubricate the u-joint bellows with Volvo Penta waterproof grease, part # 828250. Also apply waterproof grease to the six studs. P0008242 8. Slide the alignment tool, part # 3851083 through the driveshaft bearings.
Page 99 Use the same diagonal pattern to finally tighten all six locking nuts to 68 Nm (50 lbf.ft). IMPORTANT! Do not use a pneumatic or any kind of electric rotary hammer to tighten the nuts. The stud and nut threads may be damaged. P0008248 47700829 04-2013 © AB VOLVO PENTA...
Page 100 Installation, Aquamatic drive 4. Now remove any sterndrive cart used when instal- ling the trim/tilt cylinders. Apply Volvo Penta water- proof grease, part # 828250, to the trim/tilt cylinder pivot pins. Align the trim/tilt cylinder end with the upper pivot point in the gear case.
Page 101 Shift Cable, Connection IMPORTANT! The quality of the cable sheath and cable are of great importance for shift function. Use only Volvo Penta X- act or X-treme shift cables. The shift cable should have as few bends as possible and a total bend angle of 270°. The cable should also be as short as possible.
Page 102 Tighten the locking nut. 6. Secure the barrel adjuster to the shift bracket (3) with a cotter pin and washer. Bend out the cotter pin legs fully. 47700829 04-2013 © AB VOLVO PENTA...
Page 103 P0012057 5. Install the actuator above the waterline on the transom or a bulkhead. The actuator must be installed at an angle with the cable inclined upwards. α α = Min. 5° P0012019 47700829 04-2013 © AB VOLVO PENTA...
Page 104: Propeller Installation
Remove the ignition key from the ignition switch. 2 Thoroughly lubricate the propeller hub and propel- ler shaft with Volvo Penta grease (part # 828250). 3 Install the bushing (6) with the inner cone facing the sterndrive. 4 Install the propeller (5) on the propeller shaft (7);...
Page 105 NOTICE! The propeller shafts may be locked through selecting a gear or by using a piece of wood between a propeller blade and the anti-cavitation plate. 1. Apply Volvo Penta waterproof grease, part # 828250, along the entire length of both propeller shafts.
Page 106 If the propellers are not installed as described, the aft propeller may fall off and damage the unit. P0008255 7. Move the control lever to the NEUTRAL position. Both propellers must be able to move freely. 3851616 P0008256 47700829 04-2013 © AB VOLVO PENTA...
Page 107 NOTICE! The propeller shafts may be locked through selecting a gear or by using a piece of wood between a propeller blade and the anti-cavitation plate. 1. Apply Volvo Penta waterproof grease, part # 828250, along the entire length of both propeller shafts.
Page 108 An optimal result can only be achieved by trial and error, and the precise toe-in angle varies from boat to boat. For tie-bar installation, please refer to Installation instruction 3855217. P0008257 47700829 04-2013 © AB VOLVO PENTA...
Page 109 Side-mounted electronic control with neutral position lock This control has a locking function, i.e. a mechanical lock that locks the lever in the neutral position. The control also has integrated Powertrim control buttons and cables. P0004816 47700829 04-2013 © AB VOLVO PENTA...
Page 110: Inboard Applications
NOTICE! Rubber mount flexibility must never be used to compensate for deviations in the engine bed. Flexible engine mounts provide good vibration damp- ening between the engine and bed, and thus also reduce noise levels. 47700829 04-2013 © AB VOLVO PENTA...
Page 111 Propeller Shaft Systems page 18. B: Distance between reverse gear flange – support point. Minimum recommended B is 6-10 x shaft diame- ter. Max B is calculated in the same way as max L. 47700829 04-2013 © AB VOLVO PENTA...
Page 112 (A) of at least 20 mm (3/4"). P0004618 1. Rigidly installed engine mounts are recommended only for plastic molding e.g. Chockfast. 47700829 04-2013 © AB VOLVO PENTA...
Page 113 200 mm (7.9") long. Build in drainage channels so that bilge water is able to run to the bilge pump. 80 mm 10 mm 200 mm P0008295 The steel plate must be 10–12 mm (0.39"-0.47") thick 47700829 04-2013 © AB VOLVO PENTA...
Page 114 1 Align the engine with the propeller shaft and mark out the engine mount holes. 2 Drill and tap the holes in the engine bed steel strips. P0005922 IMPORTANT! Use bolt size M10 or 3/8" UNC. 47700829 04-2013 © AB VOLVO PENTA...
Page 115: Engine Installation
Install the aft engine mounts (5) on the flywheel hous- ing (including the stiffening plates (12) for the IV drive). Install the seawater hose (9) between the oil cooler (10) and the adapter (7). Secure the hose with twin clamps. 8292 IV drive 47700829 04-2013 © AB VOLVO PENTA...
Page 116 The attachment plates have oblong adjustment holes. These can be turned forwards or backwards, whichever provides best accessibility. p0005969 A = Nominal height ± adjustment: ±8 mm (±0.3") V = Lateral adjustment: ±7 mm (±0.3") 47700829 04-2013 © AB VOLVO PENTA...
Page 117 Tightening torque, engine bed bolts: Tighten hard. Tightening torque, adjuster nuts: 70 ±5 Nm (52 ±4 lbf.ft) P0008301 47700829 04-2013 © AB VOLVO PENTA...
Page 118 The alignment must be checked again a few days after launch when the boat is ready and rigged (sail- boats). P0008302 Engine Control Unit Install the engine control unit (1) on a bulkhead with the cables facing downwards or to one side. 47700829 04-2013 © AB VOLVO PENTA...
Page 119: Exhaust System
Volvo Penta supplies complete exhaust systems for such engines. A wet exhaust system may for the most part be con- structed from oil and heat-resistant rubber hoses.
Page 120 This is also ideal on boats in exposed loca- tions where waves break onto the exhaust outlet. 47700829 04-2013 © AB VOLVO PENTA...
Page 121 Always use stainless steel hose brackets. If the hose passes through a bulkhead or similar it must be pro- tected against wear. Volvo Penta silencers must be angled 5°–7,5° (a and Anti-siphon valve b) with the inlet pointing upward. Min. 350 mm (13.8") It is recommended that the exhaust outlet be located 200 mm (7.9")
Page 122 Installation back pressure must be checked if there is even the slightest doubt regarding excessive pressure (refer to the exhaust back pressure information further on in the manual). 47700829 04-2013 © AB VOLVO PENTA...
Page 123 (refer to the exhaust back pressure information further on in the manual). The hose between the exhaust elbow and the silencer may not sag; see illustration. A support can remedy this situation. P0008308 47700829 04-2013 © AB VOLVO PENTA...
Page 124 Installation back pressure must be checked if there is even the slightest doubt regarding excessive pres- sure (refer to the exhaust back pressure information further on in the manual). For further instructions, refer to the information from Aqualift manufacturer. 47700829 04-2013 © AB VOLVO PENTA...
Page 125 All transverse exhaust lines, before and after the silencer, must have an average drop of at least 10° (17 %) angle (γ). (7 ) For sailboats, refer to Main systems for sailboats. (17 ) P0008309 47700829 04-2013 © AB VOLVO PENTA...
Page 126 This type of outlet is a standard component, and must not be located on flat transoms due to the risk of back- draughting. P0008067 47700829 04-2013 © AB VOLVO PENTA...
Page 127: Back Pressure
Permissible exhaust system back pressure for given engine rpm D3-110 Permissi- D3-140–150 Permissi- D3-170 Permissi- D3-200–220 Permissi- kPa 0 psi 0 mm water column 0 1020 1530 2040 2550 3060 3570 47700829 04-2013 © AB VOLVO PENTA...
Page 128: Measuring Exhaust Back Pressure
(the dimension A can be up to 4 000 mm). NOTICE! A suitable connection nipple (3) is attached to the exhaust elbow close to the turbocharger. Dimen- sion of nipple, ⅛ - 27 NPSF 10913 47700829 04-2013 © AB VOLVO PENTA...
Page 129 • Reverse gear oil • Exhaust gases Volvo Penta cooling systems are designed for seawa- ter temperatures of max 30 °C (86 °F). Seawater inlet The seawater inlet should ideally be made in bronze alloy (brass is unsuitable as it corrodes owing to its high zinc content).
Page 130: Seawater Filter
If the filter is installed in a sailboat, this installation dimension must also be applicable at full heel. Inlet from sea cock, diameter: 32 mm (1¼") Seawater pump outlet diameter: 32 mm (1¼") P0009791 47700829 04-2013 © AB VOLVO PENTA...
Page 131: Anti-Siphon Valve
(A) between the exhaust pipe flange (lower edge) and the waterline is less than 200 mm (8"). If the valve is correctly installed, water will be prevented from siphoning into the engine. P0011387 47700829 04-2013 © AB VOLVO PENTA...
Page 132 NOTICE! The anti-siphon valve must be installed at least 500 mm (20") (A) above the waterline of a laden boat. The valve is not supplied by Volvo Penta. It must be specially made. Make sure that there is at least 120 mm (5") space above the filter to allow removal of the filter insert.
Page 133: Fresh Water System
The coolant must be mixed with clean water. Use the right engine protection. The use of corrosion pro- distilled/deionized water. The water must fulfill tection alone is not permitted in Volvo Penta engines. requirements specified by Volvo Penta; refer to Water Never use water alone as the coolant.
Page 134: Coolant Filling
Do not open the coolant filler cap when the engine is warm. Steam or hot fluid could spray out, causing severe burns. IMPORTANT! If steam or hot water spurts out the system will lose working pressure. Low system pressure causes insuf- ficient cooling! 47700829 04-2013 © AB VOLVO PENTA...
Page 135: Hot Water Connections
If this cannot be arranged a sep- arate expansion tank must be installed. Shut off valves Volvo Penta recommends that shut-off valves 2 should be installed in the extra circuit on both the supply and return sides. Locate the valves as close to the engine as possible.
Page 136 1200 mm (47") (A) above the highest engine point, or the highest point in the external circuit. The auxiliary expansion tank must be located so that it is easily accessible for level checks and filling. 47700829 04-2013 © AB VOLVO PENTA...
Page 137 MIN level to facilitate venting when coolant is filled. NOTICE! The Volvo Penta auxiliary expansion tank kit must be used when installing accessories such as cabin heaters, etc. The accessory must be installed above the engine-mounted expansion tank.
Page 138: Venting The System
(4) must be installed. Venting nipple Hot water heater IMPORTANT! Heater Make sure the system is vented after installing a hot water heater. Then check the coolant level. Expansion tank 47700829 04-2013 © AB VOLVO PENTA...
Page 139 9.25 m (30.33 ft.) is permissible between the steer- ing position and the rudder when a DS unit is installed. The following instructions provide general information applicable to all types of installations. P0006084 Hydraulic systems 47700829 04-2013 © AB VOLVO PENTA...
Page 140 250 mm (10"). Metal clamps must not be used. Cut the hoses to the correct length. Use a knife to cut to avoid swarf and burrs. Ensure that the ends are cut square and that they are completely clean. P0006085 47700829 04-2013 © AB VOLVO PENTA...
Page 141 Refer to the EVC system installation manual regarding the installation of controls and other EVC system com- ponents. Top-mounted control for single Top-mounted control for twin Side-mounted control for single engine engines engine D3-140A-D 47700829 04-2013 © AB VOLVO PENTA...
Page 142: Cooling System
Silica (acc. ASTM D859) <20 mg SiO P0002094 Iron (acc. ASTM D1068) <0.10 ppm Manganese (acc. ASTM D858) <0.05 ppm Conductivity (acc. ASTM D1125) <500 µS/cm Organic content, COD (acc. <15 mg KMnO ISO8467) 47700829 04-2013 © AB VOLVO PENTA...
Page 143: Fuel System
If the tanks are to be built in, the surrounding space must have good ventilation. 47700829 04-2013 © AB VOLVO PENTA...
Page 144: Fuel Tanks
IMPORTANT! An auxiliary fuel filter with water separator must be installed for use with all Volvo Penta engines. If a day tank is installed, it is advisable to connect the return line to this tank.
Page 145 WARNING! Hot fuel can cause burns. Fuel cooler Volvo Penta supplies fuel cooler kits for D3 A-C engines. A fuel cooler is recommended if a thermo- plastic tank is used. In hot regions the fuel in the tank can reach extremely high temperatures and may cause thermoplastic fuel tanks to melt.
Page 146 In boats where space is limited, the tank may be shaped in order to fit under the aft deck or similar space. P0004677 47700829 04-2013 © AB VOLVO PENTA...
Page 147 Deck filler (gland) (3) are formed where fuel is able to collect. Prohibited sag IMPORTANT! The fuel filler and ventilation must be installed such that overfilling is prevented and that fuel cannot enter the air inlets. 47700829 04-2013 © AB VOLVO PENTA...
Page 148 These pressures are valid on a new fuel filter. Measure fuel pressure by installing a T-connector at the measuring point (fuel feed pump inlet when meas- uring inlet pressure). Connect the measuring equip- ment to the T-connector. 47700829 04-2013 © AB VOLVO PENTA...
Page 149 (min. 60 mm (2.4”)). Minimum inner diameter required for - fuel feed line: 10 mm (3/8") - return hose: 10 mm (3/8") NOTICE! Use only approved flexible hoses. 47700829 04-2013 © AB VOLVO PENTA...
Page 150 The tank may be located with its upper edge max 1,0 m (3.3 ft.) above the valve cover. Nipples (1) Minimum inner diameter: 7.0 mm (0.28") Male thread: 1/4" NPTF Volvo Penta part #: 3825000 P0011383 Suction height (m) Suction pipe length (m) 47700829 04-2013 © AB VOLVO PENTA...
Page 151 The illustration shows the transition from flexible hose (3) to steel or copper pipe (2). Minimum inner diameter required for - fuel feed line: 7.0 mm (0.28") - return line 7.0 mm (0.28") 47700829 04-2013 © AB VOLVO PENTA...
Page 152 Nipples (1) Minimum inner diameter: 7.0 mm (0.28") Male thread: 1/4" NPTF Volvo Penta part #: 3825000 P0011384 Suction height (m) Suction pipe length (m) 47700829 04-2013 © AB VOLVO PENTA...
Page 153 Maximum fuel flow on D3 engines is 210 l/h (55 US gal./h). Fuel filter Select a fuel pre-filter dimensioned for the engine fuel flow. The pre-filter must have a water-separating func- tion. 47700829 04-2013 © AB VOLVO PENTA...
Page 154: Fuel Pressure
(8 Bar). NOTICE! In continual operations in the max position there is a risk that the pump will be damaged. Check the following: • Return fuel pressure; refer to Fuel Return Pressure, Check page 154 47700829 04-2013 © AB VOLVO PENTA...
Page 155 0 - (-) 30 kPa (0 - (-) 0.3 Bar) Min pressure -30 kPa (0.3 Bar) Insufficient pressure Check the following: • Fuel filter/prefilter • Fuel lines from tank • Fuel tank • The installation in regard to line dimensioning 47700829 04-2013 © AB VOLVO PENTA...
Page 156 0 - 100 kPa (0 - 1 Bar) Max pressure 100 kPa (1.0 Bar) Excessive pressure If the return fuel pressure exceeds 100 kPa (1 Bar), check: • Fuel pipes • Fuel line dimensions; refer to Installation page 146 47700829 04-2013 © AB VOLVO PENTA...
Page 157: Electrical System
EVC buss cable and the control unit cables in Volvo Penta IPS installations. Positive (+) and minus cables (-) must be fixed next to one another, not separately.
Page 158: Battery Terminology
10 V. Example: When two 12 V batteries, each with a capacity of 88 Ah, are connected in parallel, voltage will be 12 V and the total capacity 176 Ah. 47700829 04-2013 © AB VOLVO PENTA...
Page 159: Batteries, Installation
P0004705 Starting Group Battery Capacity The battery size specified below is recommended for Volvo Penta engines at temperatures down to -5 °C (23 °F). Battery voltage is 12 V. NOTICE! Battery capacity drops by around 1% per degree Celsius from +20 °C (68 °F), which must be taken into consideration in extreme temperatures.
Page 160: Accessory Battery
CCA = Cold Cranking Amps (current at cold start) Accessory Battery The use of a separate battery array for service power consumption is mandatory. Volvo Penta recommends the use of a charge distrib- utor to charge the service batteries. 47700829 04-2013 © AB VOLVO PENTA...
Page 161 Installation, Electrical System Starting Battery Cable Area In order to obtain sufficient start current from the bat- tery to the starter motor, Volvo Penta recommends cable cross-sectional areas as described below. Measure the total cable length from the battery pos-...
Page 162: Battery Charging
Ensure thorough ventilation, especially if batteries are charged in con- fined spaces. NOTICE! Always switch off charge current before the connections are removed. 47700829 04-2013 © AB VOLVO PENTA...
Page 163: Main Switch
Standard Protection min. temperature, rating max. ≤48 V 180 A 1 000 A 450 A +85 °C SAE marine IP 66 +185 °F J1171 Alternator connnections P0008277 B1+. Battery positive (+) LIN. Communication interface 47700829 04-2013 © AB VOLVO PENTA...
Page 164 Always install a circuit breaker to protect the electrical system. P0004719 Sensor cable Circuit breaker, accessories 12 V/24 V Circuit breaker, bow thruster, anchor capstans etc. (large con- sumers) NOTICE! Connect to start array, negative 47700829 04-2013 © AB VOLVO PENTA...
Page 165: Connection Points
One circuit is used to start the engine and the other circuit for other electrical equipment. 1 Alternator 2 Main switch 3 Split charge relay 4 Start battery 5 Service battery 6 To consumers 7 Next start battery (twin installation) 47700829 04-2013 © AB VOLVO PENTA...
Page 166: External Accessories
If a 230 V system is installed, this part of the electrical panel must be clearly marked. NOTICE! Make sure that all components used are suit- able for marine environments. Spray all electrical equipment with water repellent spray. 47700829 04-2013 © AB VOLVO PENTA...
Page 167 Calculate cable area for power consumers • Measure the distance from the terminal block to the accessory. Multiply the distance by two. • • Then calculate the cable area according to the chart . P0004723 47700829 04-2013 © AB VOLVO PENTA...
Page 168 26,65 0.041 connection. 33,61 0.052 Total voltage drop when applying the above 0 (1/0) 53,46 0.083 table: 00 (2/0) 67,40 0.104 12 V system 0.4 V 000 (3/0) 84,97 0.132 0000 (4/0) 107,16 0.166 47700829 04-2013 © AB VOLVO PENTA...
Page 169: Fire Extinguishing System
1 Pin 1 R (+) 2 Pin 2 SB (-) 3 Accessory cable kit, 10 m (32.8 ft.) 4 Fire extinguishing system (+)86 (-) 85 5 From main switch (+) or accessory relay (ignition switch) P0006324 47700829 04-2013 © AB VOLVO PENTA...
Page 170: Alternative Installation
1 Pin 1 R (+) 2 Pin 2 SB (-) 3 Accessory cable kit, 10 m (32.8 ft.) 4 Fire shut-off unit (+)86 (-) 85 5 Main switch (+) Do not use accessory relay for EVC P0006326 47700829 04-2013 © AB VOLVO PENTA...
Page 171: Launching And Sea Trial
3 Remove the cover (P) on the pump. The fluid must reach all the way up to the hole. Fill with Volvo Penta Power Trim and power steering fluid as nec- essary. 4 Replace the cap and tighten to 2–4 Nm (1.5–3 lbf.ft). 47700829 04-2013 © AB VOLVO PENTA...
Page 172 Check valves. • Check hull fittings. Engine: • Top up lubrication oil. • Check the status of drain valves and plugs. • Coolant. P0006343 Inboard engines, reverse gear: Oil level, ATF oil • P0002487 47700829 04-2013 © AB VOLVO PENTA...
Page 173 P0005976 • Water-lubricated stern bearing: vent and grease the rubber seal. Pump approx 1 cm (0.06 in ) water- proof grease into the rubber seal, Volvo Penta part # 828250. 47700829 04-2013 © AB VOLVO PENTA...
Page 174: Fuel System, Check
EVC system checklist The following actions must be taken before the system is started: 1 Complete calibration 2 Start of EVC display(s) 3 Fault code checks Pre-start checklist 47700829 04-2013 © AB VOLVO PENTA...
Page 175: Start Method
(are) activated. Check the tachometer display If a fault has been registered it will be indicated on the tachometer display. 47700829 04-2013 © AB VOLVO PENTA...
Page 176: Start The Engine
Allow the starter motor to cool for at least five minutes (if possi- ble) before making a new start attempt. 47700829 04-2013 © AB VOLVO PENTA...
Page 177: After Starting
IMPORTANT! Never race the engine when it is cold. 4 Check the oil level in the reverse gear when it has reached operating temperature. P0002487 47700829 04-2013 © AB VOLVO PENTA...
Page 178 Check that all equipment such as lanterns, instru- ments etc. is functioning normally. P0008272 Check idle revolutions Idle revolutions depend on engine type. Refer to the EVC system installation manual if idle revolutions must be adjusted. 47700829 04-2013 © AB VOLVO PENTA...
Page 179 Note the limit specified by the man- ufacturer. 4 Check engine oil level when the engine is cold. Wait 15 minutes if the engine is hot. P0004766 47700829 04-2013 © AB VOLVO PENTA...
Page 180: Sea Trail
Also check that the water lubrication works well at planing speed and above. 5 Check that steering and controls are correctly con- nected and correspond to boat movements. Checks after sea trials: Fluid levels in power steering and Power trim. 47700829 04-2013 © AB VOLVO PENTA...
Page 181: Alphabetical Index
Starting Group Battery Capacity......157 Exhaust Bellow............80 Starting the Engine (Cold Start)......172 Exhaust Line, Dimensioning........118 Steering Cable............85 Exhaust Outlet..........79, 124 Steering Cable to Powersteering Cylinder, Exhaust System............. 117 Installation..............87 47700829 04-2013 © AB VOLVO PENTA...
Page 182 Steering System..........85, 137 Steering System, Function Check......89 Sterndrive Installation..........94 Sterndrive, Installation..........97 Transom..............68 Transom Shield Installation........63 Transom, Cutout..........69, 71 Transom, support lines..........64 Water level at maximum load........63 Water Quality............140...
Page 183: Report Form
We would prefer you to write in English or Swedish. From: ...................................................................... Refers to publication: ............................... Publication no.: ..............Issued: ..............Suggestion/reasons: ........................................................................................................................................................................................................................................................................................................................Date: ............. Name: ............AB Volvo Penta Technical Information SE-405 08 Göteborg Sweden...

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