Volvo Penta — Cylinder liners and pistons, removing
Repair & overhaul
From a Volvo Penta service manual — check it applies to your exact model before use.
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Before you start
- Piston and liner are a matched pair and must be kept together.
Procedure
- Remove cylinder head and oil sump.
- Fit holders 2666 (10 ltr) or 8043 (12 ltr) if liner stays in engine.
- Turn crankshaft so piston is at top firing position; remove piston cooling nozzle.
- Turn crankshaft to access big-end cap screws.
- Remove big-end cap and lift off piston and connecting rod; scrape off soot edge.
- Mark piston and liner before removal to refit in same place.
- Remove cylinder liner with extractor 6645, supports 6394/6395 and plate 2089 (10 ltr) or 2955 (12 ltr).
- Remove circlips for the gudgeon pin.
- Tap out gudgeon pin with drift 2013 and handle 1801.
- Remove piston rings with a piston ring rod.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Source: Volvo Penta service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.