Engine Removal and Installation
Section 6: Engine Removal and Installation Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Sealants, Lubricants and Adhesives . . . . . . . . . . . . . . . . . . . . . 139 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Exhaust Pipe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Engine Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Connect Exhaust Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Connect Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Connect Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Rear Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Determining Minimum Engine Height . . . . . . . . . . . . . . . . . . . . 154 Safety Warnings Before working on any part of the engine, read the Safety section at end of this manual. Proper installation is important for the safe, reliable operation of all mechanical products. The procedures we recommend and describe in these instructions are effective methods to be followed when removing or installing the engine. Some of these methods require the use of tools specially designed for the purpose. The special tools should be used when and as recommended.
Special Tools Alignment Tool 3851083-0 Universal Handle 3850609-3
Sealants, Lubricants and Adhesives Volvo Penta Sealing Compound 1141570 Volvo Penta Grease 828250 3M Adhesive
Engine Removal NOTE! Before removing engine, check engine height. See Determining Minimum Engine Height. Check engine clearance between front of engine and engine compartment bulkhead prior to starting work. If clearance is less than 6 in. (15,2 cm), the sterndrive must be removed to disengage U-joint shaft from engine coupler. See Sterndrive and Transom Bracket Service Manual. Warning! VPA 7743358 03-2003
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