Volvo Penta — Removing the cylinder liners and pistons
Repair & overhaul
From a Volvo Penta service manual — check it applies to your exact model before use.
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Before you start
- Removal should not be carried out until it is found the liner cannot be used due to wear or damage
Procedure
- Remove the cylinder heads and oil sump (TMD100C: remove the rear inspection cover and unscrew the oil strainer first).
- Fit liner holders 2666 (100-series) or 2667 (120-series) if the liner is to remain.
- Remove the big-end bearing cap and carefully tap up the connecting rod until the rings clear the liner.
- Lift out the piston together with the connecting rod, taking care not to damage the cooling jets.
- Remove the cylinder liners using puller 6645 and support legs 6394 with the appropriate puller plate.
- Remove the circlips and withdraw the gudgeon pin using 1801 and 2013.
Tools required
- 999 1801-3 Amazon
- 999 2013-4 Amazon
- 999 6394-4 (2x) Amazon
- 999 6645-9 Amazon
- 999 2666-9 Amazon
- 999 2667-7 Amazon
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.