Volvo Penta 2001 loose engine speed control lever

[Yara]

I thought the problem was a fuel problem, so I started a thread Volvo-Penta 2001 Fuel problem
Turns out the answer was the engine speed control lever slipping on the concentric shaft. If you refer to the above thread, part of the problem is a strange split washer which is supposed to locate the arm on the square part of the shaft. I found another spare parts diagram which shows another version with the same part number, which is a circlip. Does anybody out there know the story of these parts? (Parts 31 and 34 on the exploded views.)

 

[Bilgediver]

Both those items will if the correct size do the job and locate in the groove on the shaft however the circlip is easier to remove for maintenance. The washer that was previously there was just a spring washer and not really suitable.

The split washer is an E clip and you might find on Amazon but have to buy a box however maybe find in Halfords.


Amazon.co.uk : circlips

 

[VicS]

I f there is a groove in the shaft a circlip, or E clip, will probably be the best idea , otherwise it will need a "Starlock" type washer.

In the photo it looks as though there is a wave washer in there. Maybe there should be a wave washer and either a Starlock washer or e-clip

 

[Bilgediver]

I f there is a groove in the shaft a circlip, or E clip, will probably be the best idea , otherwise it will need a "Starlock" type washer.

In the photo it looks as though there is a wave washer in there. Maybe there should be a wave washer and either a Starlock washer or e-clip

There was an earlier thread in this Vic and what was fitted was a wave washer and possibly out of correct location, which just acted as a spacer and did not secure the arm on the shaft. an E clip would be ideal as I believe there is a groove for it and easy to remove.


Volvo-Penta 2001 Fuel problem

 

[VicS]

There was an earlier thread in this Vic and what was fitted was a wave washer and possibly out of correct location, which just acted as a spacer and did not secure the arm on the shaft. an E clip would be ideal as I believe there is a groove for it and easy to remove.

Yes that is where the photo I referred to resides;

I agree the wave washer does not look right.

 

[Ceirwan]

Looks like a C-Washer that has been ground flat on one edge.

You can still get a replacement from Volspec.


Typically overpriced VP spares though, I'd just follow the above advice & use a circlip or C-washer.

 

[Bilgediver]

Yes that is where the photo I referred to resides;

I agree the wave washer does not look right.

For Volvo prices you can get a box of assorted on Amazon

https://www.amazon.co.uk/FIXMAN-262...locphy=1007326&hvtargid=pla-421793618349&th=1

 

[Yara]

It would be so easy to sort this out if I had the engine on a workbench! The VP spares diagrams do not accurately reflect the actual shapes. From what I can see, the groove in the shaft is quite wide, and that allows the lever arm to drop partly into it, even when the circlip is in place. The "circlip" is a weird design, and there is only a tiny bit stopping it from falling out, which it has done in the past. Should have raised alarm bells!
The other washer design I presume requires to be presssed along the shaft until it springs into the slot. Not easy to do in-situ and worse to remove. Maybe that is why they came up with the circlip variant. Had to squeeze it a bit to get it to stay on, which is why it looks a slightly wavy.

 

[Yara]

The more I think about it, the standard E clip looks like a solution. The Volvo version in the photo tries to compensate for the wider groove with the bent tabs, however it does not sit up straight in the groove. Maybe I can just use multiple E clips to fill the groove, and achieve some rigidity as well as redundancy.

 

[Ceirwan]

The other washer design I presume requires to be presssed along the shaft until it springs into the slot. Not easy to do in-situ and worse to remove. Maybe that is why they came up with the circlip variant. Had to squeeze it a bit to get it to stay on, which is why it looks a slightly wavy.

Actually I think you have it the wrong way around.
Starlock washers (the other type you refer to) are generally used to cut down on assembly time, they're self aligning and you just push them onto the shaft & they click into place.
Taking them off can often damage them,

 

[Yara]

Looking at the large kg numbers for the force required to fix and remove a starlock washer, the total impracticality of in-situ fitting is clear. No doubt that is why Volvo changed to circlip type, albeit not a wonderful design thereof. I have ordered some E type circlips to try. Will report the results. Expect to need at least 2 in the slot, which looks like 3mm wide.

 

[Yara]

Two off stainless 12mm E type circlips fixed the problem. Tricky in the confined access, but I had spares when the first tries disappeared into the bilge.
Now my next problem is the cooling system....

 

[Ceirwan]

Two off stainless 12mm E type circlips fixed the problem. Tricky in the confined access, but I had spares when the first tries disappeared into the bilge.
Now my next problem is the cooling system....

Easy fix normally.

The cooling pipe internally gets crudded up, it knocks out front to rear with anything you can find of the correct diameter.



Make sure you put it back in with the hole aligned in the same orientation it came out.

 

[Yara]

Thanks for the great photos. I presume the pipe is an interference fit - not exactly a perfect solution if alignment is critical.
I asked a couple of cooling system questions on another old thread that you might have the answers for:
Volvo 2000 series Raw water cooling

 

[Ceirwan]

It just slides back in and then you tap it back the full way with something that won't damage it.

The hole you see in the pic is what allows cooling water into the head, it doesn't need to be absolutely perfects, just pointing in about the same direction as when you took it out.
Before doing this I could only run at 1800rpm without overheating, now I can use full power and the engine is much cooler with no alarms.