Volvo Penta 3.0L GL, GS + SX-A – DPS-A Drives Service Workshop Manual

Workshop Service and Repair Manual for the 3.0L GL/GS Volvo Penta engine and SX-A / DPS-A drives This full workshop manual set covers every component, service and repair procedure in full Volvo Penta factory specification with clear concise step by step photographs and technical drawings for the 3.0L engine with torque setting values throughout where required for fasteners etc, This is the most comprehensive service manual available as used by marine engineers and boatyards the world over.

below is an exhaustive list of the items covered within this set:

3.0L ENGINE WORKSHOP MANUAL

Intake/Exhaust Manifold
Ignition Coil
Lift Bracket
Spark Plug
Rocker Arm Cover
Pushrod Cover
Valve Rocker Arm and Pushrod
Valve Lash Adjustment
Hydraulic Valve Lifter
Valve Train Components Inspect (Cylinder Head)
Valve Spring and Seal Repair
Cylinder Head Repair
Timing Gear Cover
Oil Seal Replacement
Crankshaft Sprocket
Timing Gear Nozzle Replacement
Harmonic Balancer Installation
Camshaft
Measuring Camshaft Lift
Gear and Thrust Plate
Crankshaft and Camshaft Sprocket Inspect
Camshaft and Bearings Clean and Inspect
Camshaft Bearings
Camshaft Installation
Crankshaft
Crankshaft and Bearings Clean and Inspect (Connecting Rod Bearing Clearance)
Crankshaft, Bearings and Bearing Cap Removal
Crankshaft and Bearings Clean and Inspect
Crankshaft and Bearings Clean and Inspect (Main Bearing Clearance)
Crankshaft, Bearings and Bearing Cap Installation
Crankshaft Rear Oil Seal and Housing Removal
Rear Main Bearing Oil Seal Replacement
Crankshaft Rear Oil Seal and Housing Installation
Oil Seal Retainer Replacement
Piston and Connecting Rod
Piston, Connecting Rod and Bearing Removal
Piston and Connecting Rod Disassemble
Piston and Connecting Rod Clean and Inspect
Piston Selection
Piston and Connecting Rod Assembly
Piston, Connecting Rod and Bearing Installation
Cylinder Block
Cylinder Block Clean and Inspect
Cylinder Bore Measurements
Distributor Lower Bearing
Distributor Lower Bushing and Thrust Washer Removal
Circulating Pump
Oil Pan Replacement
Oil Dipstick Tube Removal
Oil Pump
Oil Dipstick Tube Installation
Oil Filter Bypass Valve
High-Rise Exhaust Elbow Replacement
Exhaust Hose Replacement
Engine Coupler Replacement
Torque Specifications
Engine Specifications

SX-A / DPS-A DRIVES WORKSHOP MANUAL

Upper Gearcase – cross-section
Special Tools
Sealants, Lubricants and Adhesives
Sterndrive Removal and Disassembly
Upper Gear Housing Disassembly
Shift Mechanism Removal
Pinion Bearing Carrier Removal
Output Gear Removal
Lower Output Gear Disassembly
Upper Output Gear Disassembly
Universal Joint Service
Pinion Bearing Carrier Disassembly
Upper Housing Stud Replacement
Shift Mechanism Overhaul
Pinion Bearing Carrier Assembly
Lower Output Gear Assembly
Upper Output Gear Assembly
Lower Output Gear Shimming
Upper Output Gear Shimming
Pinion Bearing Carrier Shimming
Upper Gear Housing Assembly
Lower Output Gear and Shaft Assembly
Lower Output Gear Installation
Upper Output Gear Installation
Shimming Vertical Movement Of Upper Driveshaft
Pinion Bearing Carrier Installation
Top Cover Shimming
Top Cover Installation
Checking Gear Lash
Correcting Gear Lash
Checking Gear Teeth Contact Pattern
Final Assembly of Upper Gear Housing
Gear housing Installation
Specifications
Service Chart

LOWER GEARCASE

Lower Gearcase – cross-section
Special Tools
Sealants, Lubricants and Adhesives
Sterndrive Removal and Disassembly
Lower Gearcase Disassembly
Propshaft and Bearing Housing Removal
Vertical Shaft and Pinion Removal
Propshaft Gear Removal
Gearcase Cleaning and Inspection
Lower Gearcase Assembly
Gearcase
Propshaft and Bearing Housing
Vertical Shaft Bearings
Pinion Shimming
Propshaft Gear
Vertical Shaft and Gear Installation
Setting Rolling Torque
Gear Lash
Gear Contact Pattern
Final Assembly
Lower Gearcase Installation
Specifications
Service Chart

TRANSOM SHIELD ASSEMBLY

Special Tools
Trim/Tilt Cylinder Removal
Trim/Tilt Cylinder Installation
Gimbal Ring Removal
Pivot Housing Removal
Pivot Housing Disassembly
Pivot Housing Assembly
Gimbal Ring Disassembly
Gimbal Ring Assembly
Pivot Housing Installation
U-joint and Exhaust Bellows Installation
Gimbal Ring Installation
Gimbal Housing Disassembly
Shift Cable Hose Removal
Water Tube Removal
Water Hose Removal
Anode Replacement
Trim Sender Removal
Hydraulic Lines Removal
Trim Pump Removal
Steering Bearing, Gimbal Bearing and Seal Removal
Gimbal Housing Cleaning and Inspection
Gimbal Housing Assembly
Steering Bearing, Gimbal Bearing and Seal Installation
Trim Pump Installation
Trim Sender Installation
Water Tube Installation
Water Hose Installation
Trim Sender Adjustment
Transom Shield Removal
Shift Cable Sleeve Replacement
Transom and Exhaust Seal Replacement
Transom Shield Installation
Torque Specifications
Sealants, Lubricants, and Adhesives
Service Chart