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Home›Repair guides›Service procedure for VOLVO PENTA Workshop TMC100C TMC121C TAMD121C TD100G TID100K TD121G TD120HPP TID120HPP TID121FG 1990.pdf

Volvo — Service procedure for VOLVO PENTA Workshop TMC100C TMC121C TAMD121C TD100G TID100K TD121G TD120HPP TID120HPP TID121FG 1990.pdf

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

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Procedure

  1. Turn the fiywheel in the direction of engine rotation,
  2. Remove the auxiliary drive gear cover, pump coupling and injection pump drive.
  3. Remove the key (11, fig. 122), if fitted. Remove the attaching bolts (2) and the washer (39).
  4. Fit the rear bearing {9} in the housing by using tool
  5. Press the front bearing (5) onto the shaft. Fit the spacer sleeve (6) and then press on the revolution counter {tachometer) drive (7). Fit the spacer sleeve (8} on the shaft.
  6. Fit the key (11) on 100-series.
  7. Remove the pump coupling shield plate. Remove the intermediate shaft bolts (4x), (1, fig. 123). Note! Do not remove the bolts which hold the drive flange discs on the drive flanges since this can alter the injection pump setting. Do not turn the injection pump or the engine.
  8. Run the engine warm.
  9. Adjuster screw for max. speed (sealed)
  10. Speed control lever
  11. Adjuster screw for low idle
  12. Connect the banjo nipple 6066 to the existing outlet on the outlet side of the fuel filter, see the arrow on the filter cover. (The pressure being measured after the fuel has passed through the fuel filters.)
  13. Wash the filter cover thoroughly, unscrew and discard the old fuel filters.
  14. Open the venting screw (1). Pump out about half a litre (one pint) of fuel using the hand primer pump (2) until fuel free from air bubbles flows out. Tighten the screw. {The handle on the pump is loosened by screwing it anti-ciockwise).
  15. Filler plug 5. Draining plug
  16. Ajir-venting screw 6.° Fuel inlet
  17. Tightening nut 7. Three-way cock 4 Filter element 8. Fuel outlet
  18. 2.
  19. Wash clean around the injector.
  20. Clean the injector externally.
  21. Adjustment shim
  22. Drain off the coolant (fresh-water system for marine engines). ‘
  23. Fresh-water cooled exhaust ma- nifald Injector with copper sleeve Coolant return holes (calibra- ted} Distribution channel Sea-water pump Fresh-water pump By-pass lines Thermostats Expansion tank Heat exchanger inlet, sea-water Outlet, sea-water
  24. Empty the system and flush through with water. Dis- solve 1 kg (2.2 |b.) of oxalic acid! in 5 litres (= quarts) of hot water and pour into the cooling system. Then top up with clean water. Run the engine at normal operating temperature for at least 2 hours (max. 12 hrs).
  25. Chemical formula for sodium hydro carbonate, NaHCOQ,.
  26. Drain off some of the coolant. THERMOSTATS 2. industrial engines: Remove the thermastat housing
  27. Thermostat valve
  28. Holder
  29. Sensor body
  30. By-pass valve
  31. Knock out the old sealing ring using a drift.
  32. Place the new ring on the drift 6781 and carefully tap down until the drift bottoms in the housing.
  33. Check that the reducing valve wheel {A, fig. 150) is unscrewed and connect the hose from the pressure- testing device to the adapter, 6433.
  34. Drain off some of the coolant and connect the pres- sure-testing device with a union nipple to one of the cooling system’s plugged holes.

Source: manual:VOLVO PENTA Workshop TMC100C TMC121C TAMD121C TD100G TID100K TD121G TD120HPP TID120HPP TID121FG 1990.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.