Hweiteh.Com — Service Procedure

A Hweiteh.Com service procedure — check it applies to your exact model before use.

Procedure

1. The engine bed should be built in accordance with
the following measurements.
A
B
C
D
125 mm
449 mm
572 mm
83 mm
(5.0")
(17.7")
(22.5")
(3.3")
Measurement (D) crankshaft centerline (CC) – en-
gine bed should be 83±8 mm (3.25±0.3").
Build in drain channels to allow water to drain to the
location of the bilge pump.
3. Install the engine bed drill jig, special tool 889081.
NOTE! The notch for positioning the tool. Be careful
to ensure that the plate of the tool is correctly fitted to
the shield.
For information about Jack shaft installation, please
refer to the chapter Volvo Penta Jack shaft Instal-
lation.
2. Cut a recess in the aft and starboard side of en-
gine bed to make space for the exhaust pipe. Please
refer to the figure.
200 mm (8")
130 mm (5")
300 mm (12")
CL
C
A
B
D
889081
max. 137 mm (5.4")
A = Spacer material, preferably high density material
B = Fiberglass, approx. 10–15 mm (0.4–0.6")
C = Flat bar, galvanized, approx. 10 mm (0.4"),
min. width: 80 mm (3")
W = Flat bar width
E = Engine bed min. width: 112 mm (4.4")
The engine bed should be filled, to reduce noise and
vibration.
Build up the engine bed with spacer material (A) so
that the underside of the engine mountings/ engine
rubber mountings almost rest against the bed. There
must be room for flat bars and fiberglass.
A
B
C
•
•
E
W
Engine foundation Aquamatic
33
5. Design the engine bed so that the under side of
the tool plates rest on top of the bed. Build in a flat
bar of galvanized steel, with a thickness of approx.
10 mm (3/8") and a minimum length of 250 mm (10")
and a minimum width of 80 mm (3").
6. Fit the flexible drill jig at the correct position for the
relevant engine type, D4 or D6.
7. Mark the bed with holes, 6mm (1/4") for the flexible
engine mountings. Use drill bushings marked DIE-
SEL.
Then remove the special tool.
10 mm (3/8")
889081
8. Drill and tap the holes with a thread tap. Dimen-
sion: M12 mm (1/2"UNC) or equivalent.
4. The drill jig, special tool 889081, is suitable for Vol-
vo Penta D4, D6 and V8 engines with DPH and DPR
sterndrive packages.
The positions on the rod are marked:
D4 - D6 - V8GAS.
The drill bushings on the plates are marked:
DIESEL - GAS.
The figure shows the drill jig in position D6.
34
Aquamatic applications
Steering system
NOTE! Note that no hydraulic tie bar connections are described in the illustrations. For information about the hy-
draulic tie bar system, please refer to the chapter Tie bar installation.
IMPORTANT! Plug no. 2 must never
be used, this to ensure correct oil
level in steering pump
Single installation - DPH/DPR
Main and secondary helm station
Connections to oil cooler and servo pump not shown.
Please refer to figure above.
1
2
3
7
6
8
10
9
5
4
1a
8
The relief valve (2a) is replaced by a plug
(2b) on the lowest located steering pump.
2a
2b
2
13
1
2
3
7
6
8
10
9
12
11
5
4
8
2a
Single installation - DPH/DPR
One helm station
1. Steering pump
1a. Steering pump, secondary
helm station
2. Plugged connection
2a. Relief valve
2b. Plug
3. Hydraulic hoses, low pressure
4. Pig tails
5. Hydraulic hoses, high pressure
6. Drain hose
7. 4-way connections
8. P-clamp
9. Valve house
10. Recovery tank (reservoir)
11. Servo pump
12. Oil cooler
13. T-connections
Steering system Aquamatic
35
Single installation - DPH/DPR
One helmstation
Autopilot installed
Single installation - DPH/DPR
Main and secondary helmstation
Autopilot installed
Connections to oil cooler and servo pump not shown.
Please refer to figure above.
IMPORTANT! Plug no. 2 must never
be used, this to ensure correct oil
level in steering pump
6
5
14
1
2
2a
3
7
11
4
9
12
8
10
8
1
2
3
7
6
8
10
9
5
4
2
14
1a
8
The relief valve (2a) is replaced by a plug
(2b) on the lowest located steering pump.
2b
2a
13
1. Steering pump
1a. Steering pump, secondary helm station
2. Plugged connection
2a. Relief valve
2b. Plug
3. Hydraulic hoses, low pressure
4. Pig tails
5. Hydraulic hoses, high pressure
6. Drain hose
7. 4-way connections
8. P-clamp
9. Valve house
10. Recovery tank (reservoir)
11. Servo pump
12. Oil cooler
13. T-connections
14. Autopilot
Aquamatic Steering system
36
Twin installation - DPH
One helmstation
Twin installation - DPH
Main and secondary helmstation
Connections to oil cooler and servo pump not shown.
Please refer to figure above.
1. Steering pump
1a. Steering pump, secondary helm station
2. Plugged connection
2a. Relief valve
2b. Plug
3. Hydraulic hoses, low pressure
4. Pig tails
5. Hydraulic hoses, high pressure
6. Drain hose
7. 4-way connections
8. P-clamp
9. Valve house
9a. Hoses from port drive
10. Recovery tank (reservoir)
11. Servo pump
12. Oil cooler
13. T-connections
14. —
15. Starboard shield
16. Port shield
1
2
3
7
6
8
10
9
12
11
5
4
15
16
9a
8
8
2a
1a
1
2
3
7
6
8
10
9
5
4
9a
15
16
8
8
The relief valve (2a) is replaced by a plug
(2b) on the lowest located steering pump.
2b
2a
2
13
IMPORTANT! Plug no. 2 must never
be used, this to ensure correct oil
level in steering pump
Steering system Aquamatic
37
1. Steering pump
1a. Steering pump, secondary helm station
2. Plugged connection
2a. Relief valve
2b. Plug
3. Hydraulic hoses, low pressure
4. Pig tails
5. Hydraulic hoses, high pressure
6. Drain hose
7. 4-way connections
8. P-clamp
9. Valve house
9a. Hoses from port drive
10. Recovery tank (reservoir)
11. Servo pump
12. Oil cooler
13. T-connections
14. Autopilot
15. Starboard shield
16. Port shield
Twin installation - DPH
One helmstation
Autopilot installed
Twin installation - DPH
Main and secondary helmstation
Autopilot installed
Connections to oil cooler and servo pump not shown.
Please refer to figure above.
IMPORTANT! Plug no. 2 must never
be used, this to ensure correct oil
level in steering pump
1
2
3
7
6
8
10
9
12
11
5
4
15
16
14
9a
8
8
2a
14
1
2
3
7
6
8
10
9
5
4
9a
15
16
8
8
The relief valve (2a) is replaced by a plug
(2b) on the lowest located steering pump
2
2a
2b
1a
13
Aquamatic Steering system
38
Twin installation - DPR
One helmstation
Twin installation - DPR
Main and secondary helmstation
Connections to oil cooler and servo pump not shown.
Please refer to figure above.
1. Steering pump
1a. Steering pump, secondary helm station
2. Plugged connection
2a. Relief valve
2b. Plug
3. Hydraulic hoses, lo

Source: manual:7746265 Installation Manual D4D6 IPS Aqua Inboard.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.