Professional Documents
Culture Documents
TMD102A, TAMD102A/D,
TAMD103A, TMD122A
TAMD122A/C/D/P-A/P-B/P-C
Group 21 Engine body
Marine engines
TMD102A • TAMD102A/D • TAMD103A
TMD122A • TAMD122A/C/D
TAMD122P-A/P-B/P-C
Contents
Safety information ................................................. 2 Special tools ......................................................... 10
Introduktion .......................................................... 2 Design and function ............................................. 14
Important .............................................................. 2 Engine, general ................................................... 14
General information .............................................. 5 Positioning of rating plates .................................. 14
About the Workshop Manual ................................ 5 Engine performance ............................................ 16
Spare parts ........................................................... 5 Description of components .................................. 19
Certified engines ................................................... 5 Repairs .................................................................. 23
Repair instructions ................................................ 7 Cylinder head ...................................................... 23
Our joint responsibility .......................................... 7 Cylinder block ...................................................... 34
Tightening torques ................................................ 7 Timing gears ........................................................ 42
Angular torque ...................................................... 8 Camshaft ............................................................. 46
Lock nuts ............................................................. 8 Crankshaft ........................................................... 50
Strength classes .................................................. 8 Flywheel .............................................................. 54
Sealant ................................................................. 8 References to Service Bulletins .......................... 56
Safety instructions for Fluorine rubber .................. 9
1
Safety Information
2
General Information
Avoid skin contact with oil! Prolonged or fre- Batteries must never be exposed to naked
quent skin contact with oil can degrease the flames or electrical sparks. Never smoke in the
skin, resulting in irritation, drying out, eczema, vicinity of batteries. Hydrogen develops when
and other skin complaints. Used oil is more dan- batteries are charged, which in combination with
gerous than new oil from the health care point of air forms an explosive gas. This gas is highly
view. Use protective gloves and avoid oil inflammable and very explosive. One spark from
drenched clothes and rags. Wash your hands connecting the batteries incorrectly is sufficient
regularly, especially before meals. Use special to cause the battery to explode and cause inju-
hand cream to counteract drying out, and to ry. Do not touch the connection when starting
simplify cleaning the skin. (risk of spark) and do not lean over the batter-
ies.
3
General Information
Never work alone when heavy components are When cleaning with high-pressure wash, ob-
to be dismantled, even when safe lifting (e.g. serve the following: Never point the jet of water
lockable block and tackle) equipment is used. In at seals, rubber hoses, or electrical compo-
most cases, two persons are required even nents. Never use the high-pressure function
when lifting equipment is used: one to handle when washing the engine.
the equipment and one to make sure that com-
ponents are not damaged. When working on-
board a boat always make sure in advance that NOTE! Pressure pipes must not bent, turned, or
there is sufficient space to allow dismantling in exposed to other strain. Replace damaged pres-
situ, without the risk of personal injury or dam- sure pipes.
age to materials.
4
General Information
Spare parts l Only Volvo Penta Genuine Spare Parts intended for
the certified engine version must be used.
Spare parts for the electrical and fuel systems are
l Service of injection pumps, pump settings, and
subject to different national safety requirements, e.g.
injectors, shall always be conducted by an author-
U.S. Coast Guard Safety Regulations. Volvo Penta
ised Volvo Penta workshop.
Genuine Spare Parts comply with these requirements.
All types of damage resulting from the use of non l The engine must not be rebuilt or modified in any
genuine Volvo Penta spare parts for the product in way, with the exception of the accessories and
question will not be regulated by the warranty under- service kits that Volvo Penta has developed for the
takings of Volvo Penta. engine.
5
General Information
l Installation adjustments on exhaust pipes and IMPORTANT! Use only Volvo Penta Genuine
supply air channels for the engine compartment Spare Parts.
(ventilation channels) must not, without due care,
be conducted since this can influence exhaust The use of non genuine parts implies that AB
emissions. Volvo Penta will no longer assume responsi-
l Seals must not be broken by unauthorised person- bility for compliance of the engine with the
nel. certified versions. All types of damage or
costs resulting from the use of non genuine Vol-
vo Penta spare parts for the product in question
will not be regulated by Volvo Penta.
6
Repair Instructions
7
General Information
8
General Information
9
Special tools
In all cases where it has been practically possible tools have been punched with their tool number, excluding the
last digit. The last digit (after the hyphen) is a check number.
10
Special tools
999- 999-
2267-6 Drift for removing and fitting of ball 2659-4 Press tool for fitting of crankshaft gear
bearings in pulley, coolant pump. 2666-9, Tool (min. 2 pcs) for pressing down of
Fitting drift for bearings, injection 8043-5 cylinder liner when measuring height of
pump drive device. Counterforce liner collar above block plane, 102/3 and
when pressing out rocker arm bushing. 122 series.
2479-7 Holder for dial indicator when 2677-6 Drift for removing and fitting of rocker
checking height of liner collar above arm bushing
the block plane.
2953-1 Drift for fitting of valve guides, 122
2529-9, Drift for removing and fitting of series
2952-3 connecting rod bushing, 102/3 and 122
series 6065-0 Manometer with hose for checking of
fuel’s feed pressure or turbo boost
2655-2 Extractor for polygon hub on crankshaft pressure.* When checking feed pressure
2656-0 Fitting tool for polygon hub on crankshaft use also banjo nipple 6066.
2658-6 Extractor for crankshaft gear * NOTE! The same tool should not be used for checking both the
feed pressure and boost pressure.
11
Special tools
999- 999-
6088-2 Fitting tool for rear crankshaft seal 6668-1 Drift for fitting of valve guide (inlet), 102/3
6394-4 Supports (2 pcs) for liner extractor 6645 series
6395-1 Supports (2 pcs) for liner extractor 6645 6669-9 Drift for fitting of valve guide (outlet),
102/3 series
6400-9 Impact hammer
6683-0 Connection washer for pressure testing
6599-8 Plate for pressing in liner of cylinder head, 122 series
6643-4 Extractor for injector 6685-5 Clamp for pressure testing of cylinder
6645-9 Extractor for liner, used together with head, 102/3 series
6394 and 6695 6772-1 Tool for checking of camshaft lift height
6662-4 Pressure testing device for cooling sys
tem
12
Special tools
13
Design and function
The engines are online, six-cylinder, four-stroke marine diesel engines with direct injection. They are fitted with
heat exchangers (alt. connecting parts for keel cooling) for thermostatically controlled fresh water cooling.
The engines are lubricated by a pressure lubricating system, where an oil pump presses oil to all the lubricating
points. On TAMD102A, TAMD102D, TAMD103A and the 122 series, the pistons are oil cooled by means of spe-
cial nozzles placed in the cylinder block.
All engines have wet replaceable cylinder liners.
The engines are fitted with an exhaust driven turbocharger, which is lubricated and cooled by engine oil. The tur-
bine housing is fresh water cooled to reduce the radiation heat to the engine compartment.
TAMD102A, TAMD102D, TAMD103A and the TAMD122 series are also fitted with a seawater cooled aftercooler
which reduces the temperature of the intake air and increases the engine output. The combustion and exhaust
system temperatures are also lower.
TAMD122P–C TD MG5091SC–E
Serial number XXXXXXXXXX XXXXXXXXXX
868862 3590205
Product number Product number
TAMD122P-B,
TAMD122P-C
Certification plate:
EMISSION APPROVED IN ACCORDANCE TO THE
REQUIREMENTS OF SAV.
APPROVAL NO: xxxxxxxxxx
DATASET: 874138
14
Design and function
ENGINE
TAMD122P–A TD MG 5114 SC
XXXXXXXXXX XXXXXXXXXX
868769 3905920
Product number Product number
Other engines
TA Identification plate:
MD
10 Engine designation Product No.
2/3
TAMD122P-A 868769
No. xxxxxxxxxx / xxxxx
Serial number Basic engine No.
15
Design and function
Engine presentation
TMD102A, starboard
1. Distribution box with semi-automatic fuses
2. Air filter
3. Filter for crankcase ventilation
4. Filler, oil
5. Oil cooler
6. Inlet pipe
7. Expansion tank
8. Filler, coolant
9. Vibration damper
10. Seawater pump
11. Oil bilge pump
12. Oil filter
13. Starter motor
14. Reverse gear
15. Oil cooler, reverse gear
TAMD102A, starboard
1. Air filter
2. Distribution box with semi-automatic fuses
3. Aftercooler
4. Scavening pump
5. Heat exchanger
6. Filler, coolant
7. Extra alternator
8. Alternator
9. Vibration damper
10. Extra drive output
11. Bilge pump
12. Oil bilge pump
13. Oil filter
14. Starter motor
15. Reverse gear
16. Oil cooler, reverse gear
TAMD102D, port
1. Heat exchanger
2. Filler, coolant
3. Fuel filter
4. Smoke limiter
5. Aftercooler
6. Filler, oil
7. Filter for crankcase ventilation
8. Air filter
9. Water cooled exhaust elbow
10. Turbocharger
11. Reverse gear
12. Stop solenoid
13. Governor
14. Dipstick
15. Injection pump
16. Feed pump
17. Alternator
16
Design and function
TMD122A, port
1. Heat exchanger
2. Filler, coolant
3. Fuel filter
4. Smoke limiter
5. Injection pump
6. Stop solenoid
7. Filler, oil
8. Filter for crankcase ventilation
9. Air filter
10. Exhaust elbow
11. Turbocharger
12. Reverse gear
13. Fresh water filter
14. Dipstick
15. Inspection panel
16. Feed pump
17. Alternator
18. P.T.O. for hydraulic pump
TAMD122A, starboard
1. Air filter
2. Filter for crankcase ventilation
3. Filler, oil
4. Aftercooler
5. Oil cooler
6. Inlet pipe
7. Filler, coolant
8. Heat exchanger
9. Vibration damper
10. Seawater pump
11. Pipe for bilging of oil pan
12. Oil filter
13. Starter motor
14. Distribution box with semi-automatic fuses
15. Reverse gear
16. Oil cooler, reverse gear
TAMD122P-A, port
1. Heat exchanger
2. Filler, coolant
3. Fuel filter
4. Smoke limiter
5. After cooler
6. Filler, oil
7. Filter for crankcase ventilation
8. Air filter
9. Water cooled exhaust elbow
10. Turbocharger
11. Reverse gear
12. Shut-off valve, fuel
13. Governor
14. Dipstick
15. Injection pump
16. Feed pump
17. Alternator
18. Inspection panel, coolant
17
Design and function
TAMD122P-A, starboard
1. Air filter
2. Filter for crankcase ventilation
3. Aftercooler
4. Oil cooler
5. Induction pipe
6. Filler, coolant
7. Inspection panel, coolant
8. Heat exchanger
9. Vibration damper
10. Seawater pump
11. Oil filter
12. Starter motor
13. Distribution box with semi-automatic fuses
14. Reverse gear
15. Oil cooler, reverse gear
1 2 3 4 5 6 7 8 9
TAMD122P-B, TAMD122P-C, port
1. Heat exchanger
2. Inspection panel, coolant
3. Filler, coolant
4. Fine filter for fuel
5. Electronic Diesel Control (EDC) control
module box
6. Injection pump
7. Distribution box with semi-automatic fuses
8. Water cooled exhaust elbow
9. Turbocharger
10. Reverse gear MPM IRM311
11. Flexible engine suspension
12. Oil pan
13. Electric governor
14. Dipstick
15. Manual feed pump
16. Alternator
16 11 15 14 13 12 11 10
1 2 3 4 5 6 7 8
TAMD122P-B, TAMD122P-C, starboard
1. Oil cooler, reverse gear
2. Air filter
3. Filter for crankcase ventilation
4. After cooler
5. Oil cooler, engine
6. Oil cap
7. Expansion tank
8. Level glass, coolant
9. Seawater pump
10. Oil filter, engine
11. Alt. pos. of dipstick
12. Starter motor
13. Dipstick, reverse gear (MPM IRM311)
14. Oil filter, reverse gear
14 13 12 11 10 9
18
Design and function
Description of components
TMD102A
TMD102A is a further development of TMD100C and
was introduced from engine number 1101010220/xxxx.
The most important differences are:
l The cylinder block is provided with a plane for a
bypass oil filter. The flow of coolant round the cy
linder liners has been improved by the introduction
of a horizontal shelf round the top part of the liner.
The oil channels for the camshaft bearings have
been improved.
l The base of the cylinder head has been made ap-
prox. 3 mm (0.118") thinner, making it more flexible.
Together with new screws and modified torque this
ensures higher clamping force on the sealing union
to the block.
l The outlet valve seat has been made thinner and
has a greater grip between seat and cylinder head.
l New and thicket upper sealing ring for the cylinder
liners, 2.4 mm (0.09"), in new material (EPDM rub-
ber).
l New 5-hole distributors with hole diameter 0.34 mm
(0.0134").
l A new aluminium oil pan replaces the cast iron pan.
The inspection panels are still made of cast iron.
TAMD102A
TAMD102A is a further development of TMD102A.
The most important differences are:
l Higher output.
l Aftercooler (same as TAMD122).
l New cylinder block with piston cooling.
l New pistons. Upper compression ring of “Keystone”
type (trapezoid shaped).
l Modified compression ratio, 15:1.
l New cylinder head with modified guides for the inlet
valves (for improved air rotation).
l New valves with greater valve clearance.
l New oil pump with higher capacity.
l New oil pan, modified (also used on TMD102).
l New injection pump, 12 mm (0.47") pump element.
l Modified injection angle.
l New pressure pipes.
l New turbocharger.
l New air filter, washable.
l Larger seawater pump – 2" (same as on the 122
series).
l New vibration damper (same as on the TAMD122
series).
19
Design and function
TAMD102D
TAMD102D is a further development of TMD102A.
The most important differences are:
TAMD122D
TAMD122D is a further development of TAMD122C.
The most important differences are:
20
Design and function
TAMD122P-A
TAMD122P-A is a further development of TAMD122D. l Reinforced exhaust elbow.
The most important differences are: l New heat exchanger package (4-circuit heat ex-
changer with copper/nickel alloy pipes).
l Higher output.
l New pressure cover on the expansion tank.
l New connecting rods with trapezium shaped
gudgeon pin end. l Seawater pump with higher capacity.
l New piston rings (upper piston ring of Keystone l New aftercooler with higher capacity.
type, (trapezium shaped)). l New more efficient air filter with replaceable paper
l New cylinder liners. insert.
l New inlet valves, Nimonic. l A solenoid valve replaces the stop solenoid (the
valve reverses the feed pump function on stop).
l Greater valve clearance. Inlet: 0.50 mm (0.02") –
outlet: 0.80 mm (0.03"). l Rubber suspended distribution box.
l New injection pump with modified setting. l Transducer and sensor for the engine’s oil pres-
sure are mounted separately with rubber suspen-
l Double action feed pump with higher capacity. sion.
l New 5-hole distributors with higher opening pres- l Reinforced insulation of engine cabling (corrugat-
sure. ed plastic hose in PA66) with damp proof connec-
l Pre-tensioned pressure pipe. tions.
l New larger turbocharger with fresh water cooled l Harder rubber pads (70 shore).
turbine housing (Schwitzer S4DW).
21
Design and function
l New injection pump provided with electronic gov- l The distribution box has been moved to the left-
ernor. The governor includes an electromagnet hand side of the engine.
that activates the injection pump’s control rod and l The engine has been provided with a cover
thereby the injected fuel volume (engine output). placed over the exhaust elbow.
l An electronics box (EDC) has been introduced,
placed in connection with the rear fuel filter.
l The fuel shut-off valve has been discontinued
(the engine is stopped via the EDC system).
l New alternator with Zener diodes, 24V/60A.
l Higher output.
l New pistons with improved piston cooling (recess
cooled).
l New upper compression ring (modified piston ring
gap).
l New piston cooling nozzles (adjusted for recess
cooled piston).
l New piston cooling valve with low opening pres-
sure.*
l New reducing valve with higher opening pres-
sure.*
l New injection pump with modified setting:
– setting: 16° ±0.5° B.T.D.C.
– stroke position, on inspection: 4.45 (±0.10) mm
(0.18 (±0.004)")
on adjustment: 4.45 (±0.05) mm
(0.18 (±0.002)")
l New type of feed pump.
l New injectors with modified nozzle position:
– nozzle retainer, type KBEL 117 P 163
– nozzle, DLLA 150 P 550 TAMD122P-C (“TAMD122P EDC”)
– complete injector, marked 567 These engines are a further development of
– opening pressure, 27.5 MPa (3989 lbf/in2) (280 TAMD122P-B.
kp/cm2) The most important differences are:
– adjustment pressure (new spring), 28.0 (+0.8)
l Updated EDC system (new EDC control module
MPa (4061 (+116) lbf/in2) (286 (+8) kp/cm2)
box and new software)
– hole diameter, 5 pcs 0.412 mm (0.016")
l Fuse (7.5 A) added for the EDC-system
* Note: These valves have also been introduced on engine
TAMD122P-A (previously delivered engines have also been l New EDC-cabling with damp proof connections
updated). (2 x 8-pin)
22
Repairs
Cylinder head, removing 11. Remove the valve covers, rocker arm mechanism
and push rods.
Special tools: 9996643, 102/3: 9992666 (at least 2)
122: 9998043 (at least 2) NOTE! To simplify removal of the rocker arm
mechanism the engine should be turned so that
1. Close the bottom valve. Drain off the engine’s the valves are closed.
coolant.
12. Remove the screws that hole the cylinder heads,
2. Close the fuel cocks. 102/3 series. Remove the insert seals between
3. Remove the leads at the batteries. the cylinder heads. Lift off the cylinder heads.
4. TAMD102/3, TAMD122: Remove the connecting 13. Remove the cylinder head gaskets, rubber seals
pipes (water/air) to the aftercooler. Release the and their guides from the block.
cables for the boost pressure sensor if there is NOTE! If the crankshaft has to be turned round:
one. Remove the aftercooler. Fit tool 9992666 for the 102/3 series and 9998043
5. Remove the air filter and filter for the crankcase for the 122 series to secure the cylinder liners.
ventilation.
6. Remove the inlet pipe.
7. Remove the requisite pressure pipes and fit pro-
tective caps. Ensure cleanliness when working
with the fuel system.
NOTE! Do not bend the pipes.
8. Remove the exhaust elbow. If only one or a few
cylinder heads are to be removed, the exhaust
pipe can be left on. In which case remove the
screws for the intended cylinder head and loosen Cylinder head, dismantling
the screws somewhat for the other cylinder
Special tool: Valve spring compressor
heads.
1. Remove the valves and valve springs. Use a
9. Remove the oil leak pipe for the injectors.
valve spring compressor to remove the valve col-
10. Remove the injectors for the cylinder head to be lets.
removed. Turn the injector with a wrench (U-15),
2. Place the valves in a valve rack in the order they
pulling it upwards are the same time. If necessary
were in the engine. TAMD102/3: Remove the
use extractor 9996643.
valve stem seal from the inlet valve guide.
3. Clean all parts. Observe special care with the
channels for oil and coolant. Inspect the tightness
with the leakage test, see page 24.
4. Remove residual soot and impurities from the
sealing surfaces on the cylinder head. 122 series:
Clean the sealing grooves. Observe care not to
damage the thin edge.
Removing injector
23
Repairs
102/3 122
24
Repairs
5. Pull out the lock ring for the knob on the reducing Cylinder head, inspection
valve. Increase the pressure by screwing in the
knob until the manometer shows 50 kPa (7.25 lbf/ The cylinder head warp must be max. 0.02 mm
in2). Hold the pressure for 1 minute, then increase (0.0008"). If the warp is more than 0.02 mm (0.0008"),
the pressure to 150 kPa (21.75 lbf/in2). Lock the or if there are blow marks, the cylinder head should be
knob by pressing in the lock ring and closing the machined or replaced.
cock. Check after 1–2 minutes if the pressure 122 series: After surface grinding new sealing grooves
drops, or if air bubbles escape into the water. must be milled.
6. Release the compressed air hose. Open the cock The flame edge does not require machine as long as
and reducing valve. Remove the test equipment. the tolerance for min. cylinder head height is main-
tained, see Cylinder head, surface grinding below.
25
Repairs
Cylinder head, milling of sealing 3. Set the dial indicator to zero to the collar.
grooves, 122 series
Special tool: 9999531
When milling new grooves the cylinder head should be
machined so that the previous sealing grooves are
completely removed.
1. Nut 5. Spindle
2. Turning handle 6. Milling head
3. Guide plate 7. Tool retainer
4. Guide pins
26
Repairs
6. Press down the tool holder and tighten the lock 5. Turn the milling tool clockwise with a uniform
screw somewhat so that it presses against the movement. The cutter is fed automatically in that
holder. the nut follows the movement and presses the
7. Place the indicator tip against the highest point spring together.
on the tool and screw the adjusting screw up until 6. Turn the tool round until it stops cutting. Remove
the correct valve is obtained on the tool. the nut and lift up the milling head.
8. Tighten the lock screw. 7. Clean the cylinder head carefully. Check the
NOTE! Check that the tool holder’s upper edge is depth of the grooves by replacing the milling head
level with the cutting head. If not, then the dial in- without the spring and nut and turning it a few
dicator has moved an extra turn. turns with hand pressure. If the tool does not cut,
the grooves are the correct depth. This check
should always be conducted because metal shav-
ings can get under the milling head collar. The
burrs on the edges of the grooves should be left.
Removing these burrs can damage the edges, ad-
versely affecting the sealing function of the
grooves.
27
Repairs
3. Put the tool holders in the milling head according 4. Move the valve sideways in the direction of the
to the letter markings and with the grooves outlet and inlet channels. Read off the valve on
turned towards the lock screws. Adjust the tool the dial indicator.
height according to previous instructions. Wear tolerances:
Inlet valve max. clearance 0.2 mm (0.0079")
Outlet valve max. clearance 0.3 mm (0.0118")
If these values are exceeded the valve guides
should be replaced.
28
Repairs
3. Press in the guides with drift 9996668 (inlet) and 1. Remove the old valve seat by grinding two dia-
9996669 (outlet) for the 102/3 series, and metrical notches in the seat and then cracking it
9992953 for the 122 series. The tools give the with a chisel, see Figure
correct height over the cylinder head’s spring
plane. IMPORTANT! Observe care to avoid dam-
aging the cylinder head.
29
Repairs
Valve seats and valves, grinding 3. Check the fit with marking dye. In the event of
poor fit, grind the valve seat again and inspect
The valve guides should be inspected, and replaced if again.
the wear tolerances have been exceeded, before
grinding.
30
Repairs
Cleaning plug
31
Repairs
A. 102/3: 9992666
122: 9998043
Submerge the cylinder head screws (including
heads) in antirust agent, part No. 282036-3 (or a
mixture of 75% Tectyl 511 and 25% paraffin). The
screws should not drip when fitted (otherwise oil
can be forced up and seen as leakage).
Cylinder head gasket and sealing rings, 102/3 series Tightening torque for cylinder head screws, 122 series
32
Repairs
m Inlet l Outlet
33
Repairs
Cylinder block 4. Remove the main bearing cap. Tap up the con-
necting rod with a hammer handle to release the
Cylinder liners and pistons, removing piston rings from the cylinder lining. Lift off the
piston and connecting rod.
Special tools: 9991801, 9992013, 9996394 (2 pcs),
9996395 (2 pcs), 9996645 IMPORTANT! Scrape off the soot edge in
the top part of the cylinder liner to simplify
102/3 series: 9992089, 9992666 (2 pcs)
removing the piston and connecting rod.
122-serien: 9992955, 9998043 (2 pcs)
NOTE! The cylinder liners and pistons can, space per- 5. Dismantle the cylinder liner with extractor
mitting, be removed without removing the oil pan. In 9996645, supports 9996394 and 9996395 and
which case, work is carried out through the inspection extractor plate 9992089 for the 102/3 series and
openings in the oil pan. 9992955 for the 122 series.
3. Turn the crankshaft until the connecting rod come 8. Remove the piston rings with a pair of piston rod
in position to remove the main bearing cap pliers.
screws. For fitting of pistons and liners, see page 39.
34
Repairs
35
Repairs
When honing in connection with replacing piston Correct height over the block plane:
rings the original honing pattern must be carefully 102 series: 0.15–0.20 mm (0.0060–0.0079")
followed to retain the lubricating function. 103 series: 0.14–0.19 mm (0.0055–0.0075")
The honing must be conducted uniformly and cut 122 series: 0.47–0.52 mm (0.0185–0.0205")
equally in both directions over the complete cylin- Removed material can be compensated for with
der liner. shims, which are available in thicknesses of 0.20,
NOTE! The correct speed must be maintained to 0.30, 0.50 mm (0.0079, 0.0118 and 0.0197"). The
obtain the correct pattern. smallest possible number of shims should be
4. It is very important to clean the liner well with hot used. Calculate the thickness of the shims with
water, a brush and detergent (never use solvent, respect to the extent of the damage and the
paraffin or diesel oil) after honing. Dry the liner height of the liner over the block plane.
with paper or a rag that does not fluff, and then NOTE! If shims are used the liner recesses must
lubricate the liner with thin engine oil. be machined to a certain extent, even if the liner
recesses in the cylinder block are undamaged, in
that the fillet radius at the bottom of the liner re-
cesses must be removed for the shim to achieve
correct contact.
2. Before milling the liner recess the surface should
be roughened up with emery paper to preserve
the sharpness of the tool, especially if the sur-
face has previously been ground with grinding
paste.
The bottom liner seals should be fitted in the
block to improve guiding the milling tool.
3. Set up milling tool 9999551 for the 102/3 series
and 9999902 for the 122 series. Make sure that
Liner recess, renovation the tool collar does not catch on intermediate wall
in the block.
Special tools: 9989876, 9992479.
102/3-series: 9992666, 9999511, 9999551
122-series: 9999902, 9999903, 9998043
Remove the bottom liner seals from the cylinder
block.
Examine the top liner recess mating plane with marker
dye. In the event of uncertainty concerning the degree
of wear, see Fitting of cylinder liners and pistons.
If there is negligible damage use grinding paste to ad-
just, see item 6. If there is more extensive damage
use milling tool 9999551 (102/3 series) and 9999902
(122 series) to adjust as follows:
A. 102/3: 9992666
122: 9998043
36
Repairs
4. Position the milling tool and yoke. The tool is Cylinder block, surface grinding
fixed on the cylinder block with screws, and ap-
propriate flat washers are placed under the screw When grinding the surface block make sure not to go
heads. Make sure that the feed screw presses on below the minimum measurements.
the tool.
5. Use a dial indicator as per the figure and screw
down the feed sleeve so that it presses lightly on
the tool. Zero the dial indicator.
A T-bar with ¾" connection and a 25 mm (0.984")
sleeve is used to turn the tool.
The tool should be turned with a uniform move-
ment while turning the feed sleeve.
Stop the feed and turn the tool a few turns.
Check the mating surface of the liner recess and
the height of the step edge at regular intervals.
The milling is stopped when 0.02 mm (0.0008")
remains to the correct height.
A = Height over block plane – crankshaft centre
6. Coat the underside of the liner collar with grinding 102/3: Min. 438.8 mm (17.276").
paste. 122: Min. 463.8 mm (18.260”)
Fit the liner and turn it backwards and forwards B = Height, lower block plane – crankshaft centre
until the grinding paste is spent (use tool 9999511 102/3, 122: Min. 120 mm (4.724")
for the 102/3 series and 999903 for the 122 se-
ries. Remove the liner and wipe off the grinding NOTE! After grinding the upper block plane the piston
paste. Repeat the grinding until a good mating height must be measured as per the instructions, see
surface is obtained. Cylinder liners and pistons, assembly, item 15.
37
Repairs
Check the piston ring gap, see figure. The ring is Connecting rod bushings,
pushed down below the bottom dead centre with a
piston for the measurement. Replace piston rings if
replacement
the gap is 1.5 mm (0.0591") or more. Special tools: 9991801,
102-series: 9992529
Check the piston gap on new rings also. For measure-
122-series: 9992952
ments, see Workshop Manual, Technical data.
1. Press out the old bushing with drift 9992529 (102
series) and 9992952 (122 series).
38
Repairs
Pistons, rings and connecting rods, Cylinder liners and pistons, assembly
assembly Special tools: 9992479, 9989876, 9996599, 9992000,
Special tools: 9991801, 9992013 885126
102-series: 9992666, 9999511
1. Fit one of the lock rings.
122-series: 9998043, 9999903
2. Oil in the gudgeon pin and connecting rod bush-
1. Carefully clean the liner recess in the cylinder
ing.
block. The sealing surfaces must be completely
3. Heat up the piston to approx. 100°C (212°F). Po- free from rust and deposits. Use detergent and a
sition the piston and connecting rod so that the brass brush, and blow dry with compressed air.
piston’s and connecting rod’s “Front” markings
NOTE! Do not use a scraper.
face the same direction. Press in the gudgeon pin
with drift 9992013 and standard handle 9991801. Clean also the groove for the bottom liner seals.
NOTE! The gudgeon pin should be able to be 2. Apply a thin layer of marker dye to the underside
pressed in easily, it must not be knocked in. of the liner flange.
Push down the liner in its recess without inserting
the sealing rings, and turn it slightly on its collar.
Use expander 9999511 for the 102 series and
9999903 for the 122 series.
39
Repairs
40
Repairs
11. Fit the clamp on the liner. 15. Turn the flywheel until the piston comes to the
12. Put the bearing shells in their positions in the top position. Check the height of the piston over
connecting rod and cap. Check that the hole in the cylinder block plane.
the bearing shell comes opposite the hole in the Place a dial indicator in a magnetic stand and
connecting rod. zero to the cleaned cylinder block plane.
Lubricate the piston and big end bearing with en- Release the magnetic stand and place the tip of
gine oil and turn the rings so that the piston ring indicator against the piston.
gaps are evenly distributed round the piston. Max. height of piston over block plane: 0.55 mm
13. Check that the arrow on the piston top and the (0.0217").
connecting rod’s “FRONT” marking are turned in
the same direction. Fit the piston and connecting
rod in the respective cylinders so that the arrow
on the piston top points forwards. Use piston ring
compressor 885126.
41
Repairs
Timing gears 4. Dip a new felt ring and rubber ring in oil and fit
them with drift 9996795. Tap in the rubber ring
Front crankshaft seals, replacement first.
1 2
FRONT
1. Felt ring
2. Rubber ring
42
Repairs
5. Remove the polygon hub’s centre screw, remove 2. Apply a string of sealant (1161231-4) on the tim-
the washer, and pull of the hub with extractor ing gear cover, see figure. Apply Permatex on the
9992655. oil pan gasket.
6. Remove the screws that hold the timing gear cov- 3. Oil in the sealing rings for the crankshaft.
er. Do not forget the screws for the oil pan. Care- 4. Fit the cover within 20 minutes.
fully tap off the timing gear cover.
Tightening torque: 40 Nm (30 lbf.ft).
IMPORTANT! Make sure not to damage the 5. Check the polygon hub and its mating surface on
oil pan gasket. Otherwise, the oil pan must the crankshaft. Cut marks can be removed with
be removed and gasket replaced. fine emery paper. Grease in the crankshaft jour-
nal with molybdenum disulphide. Fit the centring
part for tool 9992656 on the crankshaft journal.
Timing gear cover, assembly Fitting of centring part for drift 9992656
Special tools: 9992656, 1158959
For replacement of front crankshaft seals, see the
previous page.
43
Repairs
6. Heat the polygon hub to approx. 100°C (212°F). Timing gears, removing
Quickly tap on the hub with drift 9992656, see fig-
(With timing gear cover removed)
ure.
Special tool: 9992658
44
Repairs
Timing gears, inspection 2. Check that the camshaft gear’s guide pin is fitted.
Fit the camshaft gear. Do not tighten the screws.
NOTE! TAMD102D and TAMD122P-A/P-B/P-C.
3. Fit the intermediate gear as per the markings, see
The timing gears on these engines are nitro-carbu- figure. The bearing shell and thrust washer are
rized. The gears are marked “N” or “NITRO”. They can placed as per the figure. Tightening torque 60 Nm
also be recognised by their dull grey or yellow-grey (44 lbf.ft).
colour.
45
Repairs
46
Repairs
47
Repairs
Camshaft and lifters, inspection Check the bearing races and cam curves on the cam-
shaft for wear. The cams may, for example, be worn
Check with a steel ruler that the mating surface of the at an angle in axial direction. Where the damage is
valve lifters to the camshaft is spherical (convex). It slight this can be rectified by honing the cams. In the
may also be completely flat, but under no circum- event of further damage or wear, replace the cam-
stances concave (see figure). If light can be seen in shaft. When replacing the camshaft all the valve lift-
the middle of the lifting surface between ruler and lift- ers must also be replaced.
er, the lifter should be replaced.
Camshaft, measuring
Measure the camshaft’s bearing races with a microm-
eter. Max. wear and ovality 0.07 mm (0.0028"). The
linearity of the shaft is checked by means of indica-
tion. Max. radial warp in relation to end bearing: 0.04
mm (0.0016"). The lifting height (cam height) is meas-
ured with a feeler gauge.
Checking of valve lifter
A B
48
Repairs
The measurements for camshaft and camshaft bear- 5. Check the camshaft’s axial clearance:
ings are in the Workshop Manual, Technical data. For 0.05–0.18 mm (0.0020–0.0071"). Radial
lifting height, see also the table on page 46. clearance: 0.03–0.08 mm (0.0012–0.0032").
Cam wear can be estimated without removing the 6. Check the intermediate gear’s axial clearance:
camshaft, see Inspection of cam wear, on page 46. 0.05–0.15 mm (0.0020–0.0060"). Radial clear-
ance: 0.03–0.09 mm (0.0012–0.0035").
7. Check the tooth flank clearance: 0.03–0.17 mm
(0.0012–0.0067").
49
Repairs
50
Repairs
51
Repairs
10. Fit the oil pipes and the oil pan, see Workshop
Manual, Lubricating system.
52
Repairs
4. Turn the crankshaft until its oil hole is exposed. 2. Remove the crankshaft seal with tool 885341 and
Place an appropriate pin in the oil hole so that impact hammer 9996400.
when the crankshaft is turned the upper bearing
shell follow with it, see figure.
NOTE! The engine is turned in the normal direc-
tion of rotation when rolling out the bearing shell.
53
Repairs
2. Drill 1–2 holes in a tooth gap on the ring. Crack 5. Place the heated ring on the flywheel. Tap on the
the ring at the drilled hole with a chisel and then ring with a soft drift and a hammer.
remove the ring.
3. Brush clean the mating surface with a wire brush. 6. Clean the mating surfaces between crankshaft
4. Heat up the new ring with a welding flame. Heat and flywheel carefully.
uniformly. Observe care to avoid overheating, and 7. Inspect, and where appropriate replace the seal-
loss of temper. ing ring for the crankshaft.
8. Fit the flywheel as per the previous markings.
Tightening torque: 175 Nm (130 lbf.ft).
54
Repairs
55
References to Service Bulletins
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AB Volvo Penta
Service Communication
Dept. 42200
SE-405 08 Göteborg
Sweden
7739945-9 English 02–2012