How to remove and refit a Volvo Penta 290 Sterndrive and Bellows
Posted on | March 31, 2010 | No Comments
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head) that retain the horizontal hanging pins where they pass through the transom shield, the hanging pins can then be withdrawn using a piece of threaded rod and a piece of tube or similar.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
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