NOTE!

Read the Installation Manual D4/D6 Aquamatic DPH/DPR, Volvo Penta IPS, Inboard
before the installation work of IPS propulsion unit and engine is started.
Other electrical installations, please refer to Installation Manual EVCEC-C2, Electronic Vessel
Installation Reference, Volvo Penta IPS WARNING! Make sure all safety precautions are made prior to lifting to avoid personal injuries and
damage on equipment.
NOTE! Before installing propulsion unit and engine, make sure that the rest of the installation work
Control Volvo Penta IPS.
Propulsion Unit and Engine in the engine compartment has been completed. In addition, all cables and hoses must be correctly
located and clamped.

Installing the
1 Installation kit 2 Chassis no. identification 3–6 propulsion unit 4 Arrange the
clamp ring with a
separate loop as
5 Lifting force:
Max. 10000 N
Alternative lifting device.
D6 engines D4 engines Special tool 885835
IMPORTANT! shown. (2200 lbf)
Check that engine chassis no. and propulsion NOTE! Sealing
unit (SUS) chassis no. are identical. Clean (wipe) hull rings in place.
Water inlet valve
and bypass inserts.
blocking cover SUS IMPORTANT!
Water inlet valve Chassis no. Keep sealing
and water bypass Exhust bends rings and contact
Rubber surfaces on inside Clamp ring
valve and hoses lubricant of hull insert free with rubber
from grease. sealing ring

Transom Engine
chassis no. Wipe rubber
anode kit sealing rings IMPORTANT!
and apply rub- Apply grease, part
ber lubricant, no. 828250
Clamp rings, rubber Volvo Penta part
sealing rings and bolts no. 3817243.
SUS IMPORTANT!
Chassis no. Do not use vaseline
Extended or grease.
water inlet kit Propeller attache-
(Triple/Quad) ment parts

Installing the water inlet

6 Lifting force: 12 x 12M screws. Tightening torque: 7 and water bypass valves 8 Installing the engine 9 Connecting the drive shaft
10 Installing the oil cooler
Max. 10000 N 70–80 Nm (52–60 lbf.ft) WARNING! Always use both lifting B C
(2200 lbf) eyes when lifting the engine. A Check distance:
Tightening torque:
15–18 Nm
NOTE! Max. 3 mm (1/8”) Tighten the
4 x M12 screws, NOTE! Water bypass is not used on D4 Check: (11-13 lbf.ft)
Apply grease two allen screws.
placed as in figure. IPS applications. Equal loading on port and starboard NOTE! Ensure
on all bolts
Tighten cross vise, mounts by measuring distance H. there is play be-
5 mm at a time. D6 tween drive shaft
Final torque: engines coupling and gear
70–80 Nm D4 Green No lubricant box housing.
(52–60 lbf.ft) engines on shaft!
D 120–130 Nm
Check: (90–96 lbf.ft) Hose clamp
Cover Drive shaft tightening torque:
Water flange-to-flange
bypass 5–6 Nm
distance. Adjust Leave a space of approx. (3.7–4.4 lbf.ft)
valve engine if E 5-10 mm (0.2-0.4”).
F
O-ring O-ring Red needed.
NOTE! Apply corro- Check:
sion protection, part Wipe Aligning of
surfaces arrows. 385±15 mm
no. 9510227 in area H
between clamp ring (15”±0.6)
and gear housing.
Tightening torque:
70–80 Nm (52–60 lbf.ft) 24–28 Nm (18–21 lbf.ft)
Water NOTE! Unequal load- Check:
inlet Tightening torque:
ing will cause engine 25–30 Nm (18–22 lbf.ft) Equal loading on mounts.
Mounting the protective anode. Installing the valve
11 exhaust line and the water inlet and bypass hoses
vibrations. See also 9F
Arrows Check on three points using
setting tool 21244540.
Installing an exhaust riser
A Tightening torque:
Steering cable,
48–52 Nm (35–38 lbf.ft) C The need of an exhaust riser is described in F connected to Y-
Installation Manual Aquamatic DPH/DPR,
IPS, Inboard D4/D6
G Water inlet hose
12 Power supply connector on PCU

E Tightening torque: Connect positive (+)

10±2 Nm to 50A automatic fuse.
(7.5±1.5 lbf.ft) Tightening torque:
10-12 Nm SECONDARY
(7.4–9.0 lbf.ft) (reverse)
TROLLING
NOTE! Oil temp. (not used)
Wipe D6 engines: Two hose IMPORTANT! Oil pressure
surfaces NOTE! Place reduc- clamps! Apply corrosion protec-
Place O-ring in ing insert in tion, part no. 9510227,
exhaust bend hose. on all power supply PRIMARY
Hose clamps, (forward)
tightening torque: connections.
NOTE! Fit
Water 5–6 Nm (3.7–4.4 lb.ft) strain reliefs REV.PICK-UP
bypass Tighten the on all cables. (not used)
hose. four screws
IMPORTANT! Hose clamps Tightening torque:
B Apply corrosion
protection, part no.
tightening torque:
5-6 Nm (3.7–4.4 lb.ft)
Two hose
clamps!
Only D6
engines 48–52 Nm (35–38 lbf.ft) 13 Calibration
9510227, on bond- Calibrate the propulsion unit positions by
ing connections. using the parallel alignment tool, special tool
Use marine seal- D 3808507 and the VODIA tool 3838619 in combi-
ant on the through nation with the switch box, special tool 3887101.
hull fittings. Tightening torque: Please refer to Installation Manual D4/D6
25° Aquamatic DPH/DPR, Volvo Penta IPS,
Protective anode kit 10±2 Nm
(7.5±1.5 lbf.ft) Inboard and VODIA User’s Guide.
3888020 (GRP hull) NOTE! Min.
3888063 (Steel or distance between
exhaust bend Connect negative
Alu hull) Exhaust hose clamp, 3808507
NOTE! 45° and transom: (–) to starter.
D6 engines: standard elbow and Tightening torque:
25 mm (1”).
IMPORTANT! Place riser: 10–12 Nm
reducing Tightening torque: (7.4–9.0 lbf.ft)
- Do not bond the IPS units together.
insert in 20–25 Nm
- Do not bond the IPS to the engine
hose. (15–18 lb.ft)
or any other component on board
the boat. Water bypass 3838619
- Do not bond any other equipment Two hose hose. Only D6 Recommended
to the IPS external anode. clamps! engines riser angle: 45° 3887101
 NOTE! Read the Installation Manual D4/D6 Aquamatic DPH/DPR, Volvo Penta IPS, Inboard
before the installation work of IPS propulsion unit and engine is started.
Other electrical installations, please refer to Installation Manual EVCEC-C, Electronic Vessel Con-
Installation Reference, Volvo Penta IPS WARNING! Make sure all safety precautions are made prior to lifting to avoid personal injuries and
damage on equipment.
NOTE! Before installing propulsion unit and engine, make sure that the rest of the installation work
trol Volvo Penta IPS.
Jack shaft mounting in the engine compartment has been completed. In addition, all cables and hoses must be correctly
located and clamped.

Mounting the front end

1 Jack shaft installation kits A D E 2 IPS Hull and Engine 4 protective casing 5 Connecting the drive shaft, rear end (propulsion unit)
foundation A B Check distance:
Designation Qty. Ref.
Please refer to poster Installation Reference, Max. 3 mm (1/8”)
A. Drive shaft
Jack shaft, ordered length 1 (Step 3)
Volvo Penta IPS Hull & Engine foundation Tightening torque: NOTE! Ensure
Publ. No. 7747482. 48±5Nm (35±4 lbf.ft) NOTE! there is play be-
B. Jack shaft kit
M14x50 flange screw 8 IMPORTANT! No lubricant tween drive shaft
Protective casing, compl. 1 (Step 4) Check that engine chassis no. and on output coupling and gear
M10x35 flange screw 10 B propulsion unit chassis no. are identical. shaft! box housing. C
Shaft coupling 1 (Step 5)
F Exhaust riser kit
C. Catch kit
Front end catch, complete 1 (Step 6) D4 engines
M10x30 flange screw 4
Exhaust elbow kit D
Rear end catch, complete 1 (Step 7) D6 engines Tightening torque:
M10x30 flange screw 5 Connecting the drive shaft, 140±15Nm (103±11 lbf.ft)
M10 flange nut
M8x20 flange screw
3 3 front end (engine side)
Tighten the two allen
screws.
D. Cables D6 engines Tightening torque:
Extension cable, 6-pin 1 125±5 Nm
T-connector 1 (92±4 lbf.ft)
Power supply cables (+/–) 1
E. Oil distribution kit NOTE! No bolts are E
Hose unit 1 (Step 9)
C to be fasten in the Check: Li= Installed shaft length
lower two holes. Aligning of
O-ring 1 arrows.
Oil filter 1 Part no. Li (mm)
Gear box oil can, 1 lit. 1 G D4 engines D6 engines 3817450 1670–1750
F. Exhaust kit D4 engines Tightening torque, 4x: Arrows 3817451 1570–1650
Exhaust riser kit 1 (Step 10) 140±15Nm (103±11 lbf.ft) 3817452 1470–1550
Exhaust kits D6 engines 3817453 1370–1450
Exhaust elbow kit 1 (Step 10) 3817454 1270–1350
Exhaust riser kit 1 (Step 10) 3818288 1170–1250
Rubber insert, water by-pass hose, 3818289 1070–1150
∅ 50–45 mm (2”–1 3/4”) 3818290 970–1050
3818291 870–950 IMPORTANT!
G. Hoses and hose connection kit 3818292 770–850
Hose clamp, ∅ 140 mm 1 (Step 11) 3818293 670–750
Check:
Hose clamp, ∅ 66 mm 1 3818295 570–650 - Part no. and Li from the table
Exhaust hose ∅ 5” (127 mm), Mounting the rear end catch - Li is within recommended dimension
incl. bend 1 (Step 11) 7 - Adjust engine if needed
Water inlet hose ∅ 2” (50 mm)
D4 engines: Rubber insert,
1 (Step 12
A
(D6 installation is shown)
8 Installing the oil cooler
9 Installing new oil hoses to gear box and oil cooler
water inlet, ∅ 50–38 mm (2”–1 1/2”) 1 (Step 12 Loosen two
D6 engines: Water by-pass hose, screws (M14) Tightening torque 3x: Installing to Installing to
∅ 2’’ (50 mm) 1 (Step 12) from clamp C 15–18 Nm gearbox: oil cooler:
ring. (11–13 lbf.ft)

6 Mounting the front end catch

Replace: Port
- Hoses with connection side
- O-ring
Tightening torque 4x: - Oil filter
48–52 Nm (35–38 lbf.ft)
B Hose clamp Starboard
tightening torque: side
5–6 Nm Allen key no. 10.
NOTE! (3.7–4.4 lbf.ft)
Tightening Tightening torque:
torque 1x: 24–28 Nm (18–21 lbf.ft) NOTE! Connection
70–80 Nm of starboard and
(52–60 lbf.ft) port side hoses.
Tightening torque 8x: Starboard
24–28 Nm (18–21 lbf.ft) side

NOTE!
Tightening torque: Tightening torque 5x: Installing: Connecting:
10±2 Nm (7.5±1.5 lbf.ft) 35–38 Nm
(26–28 lbf.ft)
Tightening torque 1x:
70–80 Nm (52–60 lbf.ft) 12 Water inlet hose and water bypass hose 13 Shift cables, steering cables and power supply cables to the SUS
Connect positive (+) to
D6 engines only:
10 Installing exhaust elbow and exhaust riser 11 Installing the exhaust hose Water bypass
hose
IMPORTANT! Apply
corrosion protection part no.
50A automatic fuse.
Tightening torque: Steering
cable,
9510227 on all power 10-12 Nm (7.5–9.0 lbf.ft)
connected to
Installing an exhaust elbow supply connections. Y-connector
Only on D6 engines.
Installing an exhaust riser Elbow and on PCU
The need of an exhaust riser is riser
described in Installation Manual Power
D4/D6 Aquamatic DPH/DPR, NOTE! supply
Volvo Penta IPS, Inboard Place SECONDARY cables
Exhaust hose Two hose reducing (reverse)
clamps! insert in TROLLING
clamp Oil temp. (not used)
Tightening torque: tightening torque: hose.
10±2 Nm (7.5 lbf.ft) Oil pressure
20–25 Nm
(15–18 lbf.ft)
PRIMARY
Water inlet hose Hose clamp Connect negative (–) (forward)
tightening torque: to starter. NOTE! Fit
5–6 Nm (3.7–4.4 lbf.ft) Tightening torque: strain reliefs REV.PICK-UP
Water bypass Two hose 10–12 Nm (not used)
Tightening torque: on all cables.
Water bypass connection. clamps! (7.4–9.0 lbf.ft)
10±2 Nm (7.5±1.5 lbf.ft)
connection. Not D4 engines!
Two hose Rubber
45° hoods
clamps!
Connect power
25°
14 Calibration supply cables (+), (–)

7746926 05-2008
Reducing Two hose Tightening torque:
Please refer to Installation clamps!
Manual D4/D6 Aquamatic insert 10–14 Nm
DPH/DPR, Volvo Penta IPS, D4 engines only: (7.4–10.3 lbf.ft)
Recommended Inboard and VODIA User’s Attach 3” to 2½”
riser angle: 45° Guide. reducing insert