Bamboozled! - Volvo Penta 2002

[muzzaman]

Hi

I have spent all morning trying to remove the "engagement pin" that the starting handle locks into when hand cranking my Volvo Penta 2002.

I was looking for a grub screw both in the end of the shaft itself and also in the ends of the engagement pin. Unfortunately there are none, only the small pin inside the larger pin. Does anyone know how to get this out!

I have attached a photo.

Many thanks.View attachment 48412

 

[sailorman]

the inner pin looks to me like a roll pin.
if so it should be knocked out with a punch

 

[pvb]

Earlier engines used 2 rollpins, one inside the other, which is what your photo looks like - see items 15 and 15A on the diagram. Later engines used a single pin held in with a screw, items 15C and 15D on the diagram. As sailorman suggested, you'll need to drift them out.

 

[VicS]

some variation between versions ITYWF

Some do have a grub screw ( socket headed??) fitted in the end of the shaft. Some (early versions) seem to have this spring pin arrangement.

The diagram above shows both



The workshop manual describes refitting this pin with a special tool ( although I cannot find any info on its removal) and cautions against fitting with a hammer and punch or drift as that could bend the cam shaft

http://www.bluemoment.com/manuals/volvo_penta_2002_worksh.pdf

the same tool 884839 is used to press the pin out. Punching them out could also bend the shaft!

Sorry, notta lotta help.

 

[muzzaman]

Thanks everyone - that's a great help. It is definitely the pin inside the other pin version having looked at the diagram. I just need to work out how to get them out in such a confined space without bending the shaft!

 

[Len Ingalls]

The 2000 series service manual specifically states NOT to drive the pin out with hammer-you will bend the camshaft.
It should be "pushed"out with a "crowfoot"style tool. Just an FYI.
Google Volvo Penta 2000 service manual / Len

 

[Len Ingalls]

http://www.bluemoment.com/manuals/volvo_penta_2002_worksh.pdf

Page 6 Pgh 7

 

[Len Ingalls]

http://www.instructables.com/id/Cheap-and-Simple-Gear-Puller/

 

[langstonelayabout]

Hi

I have spent all morning trying to remove the "engagement pin" that the starting handle locks into when hand cranking my Volvo Penta 2002.

I was looking for a grub screw both in the end of the shaft itself and also in the ends of the engagement pin. Unfortunately there are none, only the small pin inside the larger pin. Does anyone know how to get this out!

I have attached a photo.

Many thanks.View attachment 48412

Out of interest, why would you want to remove this pin?

This morning I tried to start my boat’s engine, a Volvo 2002, only for the starter to refuse to start it. No problem I thought, I’ll use the starting handle.

And yes, some berk of a previous owner has removed the pin, and the starting handle is useless (just like the owner…)

Everyone; why would you remove the pin used to engage the starting handle?

 

[Snowgoose-1]

Interesting. When I had 2000 series engines, none would start on the handle. I believe they were used for things like tappet adjustment.