Removal / Re-fitting and replacement of Volvo Penta 290 sterndrive leg, bellows and water pickup pipe etc.

Like most Sterndrives the Volvo Penta 290 drive is a heavy unit and care must be taken to ensure that it is properly supported and that the correct tools are used during all service procedures. Make sure you have a competent and strong assistant, and that you are both wearing the correct footwear and clothing etc.

Initially the drive should be in the vertical (operational) position and the steering pivot removed from the helmet (Pos'n 1), there are usually 2 socket head screws holding it down, these should be removed from the pivot pin and the pin removed either by jiggling it from side to side using two pins or screwdrivers, or if it is really stuck the two smaller tapped holes can be used to jack the insert out by using the long stainless screws which secure the gear shift selector cover (Pos'n 2).

After removing the shift cover remove the small split pin which holds the shift cable to the mechanism (Pos'n 3) and then un-clamp the shift cable locking plate on the forward end of the intermediate housing ( Pos'n 4)

Trim the leg up as far as possible and unclamp the universal joint bellows where the clamp goes around the upper drive unit (Pos'n 5) then unclamp the exhaust bellows from the intermediate housing (Pos'n 6) , Undo the hose clamp that secures the water pickup pipe to the pickup helmet (Pos'n 7) and in the case of power trim models (MAKING SURE THE DRIVE IS PROPERLY SUPPORTED IN THE TILTED POSITION) Remove the clevis pins which hold the trim rams to the “H” frame, (retained by small split pins) it is usually possible to then lower the drive back to an upright position using the power trim but

PLEASE ENSURE THAT ALL HANDS AND BODY PARTS ARE AWAY FROM THE DRIVE DURING THIS.

volvo penta 290 Sterndrive

After the drive has returned to the vertical position make sure it is well supported under the Skeg,

Remove the two vertical lock screws (Stainless Allen cap head) that retain the horizontal hanging pins where they pass through the transom shield, the hanging pins can then be withdrawn using a piece of threaded rod and a piece of tube or similar.

It is sometimes possible to drive the pins in towards the bellows however -

IF THEY ARE TIGHT YOU WILL SWELL THEM A FEW THOUSANDS OF AN INCH AND THEY WILL GET STUCK IN THE HOLE.

So it is preferable to draw them outwards if possible.

The Drive should then be free to pull away from the boat ensuring that all hoses,cables and bellows detach themselves and ensure the shift cable passes freely through the hole in the leg.

Lift the drive away from the boat and store it safely.

The drive and exhaust Bellows can then be removed from the transom shield and the water pickup pipe removed and replaced if needed, the inner end of this has a “top hat” and it must be inserted through the shield from the inside by removing the steel inner Pickup pipe / Oil cooler/ Seacock (whichever is fitted)

On drives prior to the 290 the water pickup pipes usually have a hose clip on either end and can be removed from within the transom shield area.

Replacement is pretty much the reverse procedure, however care should be taken to ensure that all bellows and hose location diameters are cleaned and prepared correctly and all pins are cleaned using fine emery cloth if needed.

The drive should be offered up to the shield and supported on wooden blocks with an assistant holding it steady, the shift cable should be inserted through the hole in the intermediate housing.

Clip screw positions when Fitting Volvo Penta bellows

Hang the exhaust bellows clamp over the neck on the intermediate housing lift the drive into position and insert the universal joint over the intermediate shaft indexing it around to align the splines, if necessary Install the hanging pins with some light waterproof grease whilst aligning the retaining bolt grooves in each pin.

Work the bellows into place with the clamp screws in positions where they will not rub or chafe on other items (move the drive fully from side to side to ascertain this)

Pull the steering helmet back over the upper gearbox and refit the pin into the bush (apply some waterproof grease)

Secure the shift cable clamp and connect the shift cable to the actuating mechanism,

Refit the trim ram anchor pins and split pins, (take care if the leg is raised that it is fully supported until the rams are properly attached to avoid physical damage).

Replace the shift mechanism cover.

NOTE-

TO ONLY REPLACE THE DRIVE BELLOWS IT IS NOT NECESSARY TO REMOVE THE WHOLE LEG, ONLY THE TOP GEARBOX NEED BE REMOVED HOWEVER WE RECOMMEND BUYING A WORKSHOP MANUAL FOR THIS

How to remove and refit a Volvo Penta 290 Sterndrive and Bellows is a post from: Boat Accessories, Chandlers, News, Reviews, Tips, Tricks and Videos

Have Your Manufacturer's Manual Handy

If you have a copy, great. If you don't, it would be a good idea to get one. A manual will make your life easier, in the long run, it will help you to find out which oils and lubes you need, capacity needed, and of course the complete service schedule.

We have the Clymer Manuals for sale, which cover both your engine and sterndrive, and they are a great investment.

De-winterizing Your Engine

The engine is the most important bit of your boat, and since it will most like take the greatest amount of time and be the messiest, (no point in cleaning the bilges then covering them in oil again!) start here.

If you didn't change the oil at the end of last season, do so now. After running your boat all summer, it's likely that water, acids and other byproducts have built up. It's important to change the oil to prevent corrosion and excessive wear which can lead to loss of power, poor fuel economy or engine failure. At the same time you change the oil, be sure to change the oil filter. Change the oil in gearbox or the sterndrive's lower unit as well.

Next, flush the cooling system, run the engine on flush muffs, if you have a closed cooling sysytem replace the antifreeze with a 50/50 ratio of water to coolant.

Assuming you removed your batteries at the end of the season, replace them and perform a thorough engine test. 

Inspect the Canvas & Vinyl

Check your bimini top, seats, covers, and other vinyl and canvas items for tears, mildew and dirt. Repairs tears and holes, and then clean with the proper cleaner for canvas and vinyl.

The Starbrite Boat cover cleaner is great for this job, as it is not to astringent, but it gets the mould and green stuff out, quickly and easily. Follow this up with a re-waterproofing treatment, and you should get great service out of your covers all season.

Inspect the Hull

Carefully inspect the hull for blisters or other chips and cracks as well as for chalky residue. If you find blisters, repair them. If the boat's hull is chalky, it could indicate oxidation. Determine the level of oxidation, and then if needs be get to work either with a polisher or by hand with a rubbing compound, followed by a good quality polish, then final burst of elbow grease to wax the hull, giving it that much needed protection for the season ahead.

Polish the Metal and Teak

Known as brightwork, metal and teak enhance the look of your boat. If it's dull, your boat will not have the same visual appeal as it might otherwise have. Also, prolonged neglect of metal and teak can result in pitting and eventually compromise the integrity of the materials and their intended use. To protect the metal, use metal polisher like Starbrite chrome & stainless polish.

Replace and Test all Electronics

If you removed the electronics bring all them all back on board and do a thorough test to be sure they are working properly. Test the radio, GPS, compass, sounder, and any other marine electricals like your navigation lights, interior lights and if water systems etc..

Clean the Interior

Whether you have an open deck or cabin with full galley, clean the area thoroughly to remove dirt and debris.

With all these jobs done, you should be ready to get back into the water as soon as you can!
Hopefully, this year will see some better weather, so we can all enjoy the fruits of our re-commissioning labour.
Have a happy & safe season. 

De-Winterizing Your Boat is a post from: Boat Accessories, Chandlers, News, Reviews, Tips, Tricks and Videos

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