'02 Volvo Penta Engine

[Paul L]

Your story sounds a bit like Death by a thousand paper cuts

[Rustic Charm]

Originally Posted by tedsherrin

I know this is an 'old' thread, but I'm hoping to resurrect the topic of the 2000 series engines for up dates.

Three years ago I purchased my ketch with a 2003 T engine. It's been poorly looked after and neglected and had salt water dropping over it. I've removed it three times so far and am about to remove it entirely from the boat to try to stop all minor oil leaks.

Last year I found the oil cooler had corroded away beyond repair. I purchased an after market one for $3000 and that works fine.k.

Sorry, meant to say $300. Not $3k

[Rolloh]

I bought a Volvo D2-40 in 2007 not knowing they, (all) D2 models have a design flaw. The heat exchanger manifold sealing surface on the aft end is sealed by an o-ring that allows the salt water to eat away the manifold. One case I've found the user only had 30 hrs use before it failed. The coolant begins to get contaminated with salt water, we all know where this is going. Having contacted Volvo North America they said that they do not warranty the coolant system past 24 months. As a sail boat owner I've got 353 hrs in 7 years, we just don't use them that often, (the engine). It is designed to fail from the first time you start it in salt water, its only how long does it take for the corrosion to break through to the coolant is the question. In my case, about 5 years, I noticed some goo like stuff coming from the rear cap and found corrosion started at the sealing surface where the o-ring is Suppose To Keep it Out. I'm going to JB weld the sealing surface along with all the pitting under the cap and hopefully stop the problem from going further after a good flush with oxalic acid, the coolant side of the system just to be sure there is no salt water still with in the coolant area in the block. Having said all this, buyer beware of All the short comings with what ever engine you decide upon installing. Had I'd knows this, and I did do my home work back in 2007 before this problem was discovered I would have chosen something different.
Live and Learn, Rolloh

[Rolloh]

Originally Posted by S Campbell

I have found a new boat that I love, however it has a volvo penta 2002 model inboard diesel.
Is it any good?
I don't want to buy a lump of stinky steel.. I'd rather be sailing.

Thanks in advance.

NO, STAY AWAY FROM IT, THE D2 MODELS HAVE A DESIGN FLAW AT THE REAR CAP OF THE HEAT EXCHANGER. I HAVE ONE WITH 353 HOURS ON IT, THE REPLACEMENT COST $2000.00 SALT WATER EATS THE CAST IRON
UNDER THE SINGLE O-RING AND YOUR BUYING. THERE ARE MANY OTHERS WHOM FEEL THE SAME AS I, KEEP LOOKING, OR YOU'LL BE PAYING, ALLOT, OVER AND OVER FOR EVERYTHING.
ROLLO

[olaf hart]

Is this a problem for the D1 series engines as well?

[Rustic Charm]

From what I can see the problem was with the D1 engines.

Volvo D1-20.....airlock

[Rolloh]

I don't know if it (the design flaw) originated with the D1, however if it has the same bolt on water jacketed manifold with O-Ring caps on both ends, then its highly probable. I really feel for the owners of cats having 2 of these installed, double the trouble and no relief from Volvo as to a recall of a bad product. I might add that after dis assembly the heat exchanger looks as new.
Rollo

[Rustic Charm]

that looks identical to my 2003T model heat exchanger. Mine has to be replaced this year because the casing has corroded away so badly it can't be repaired any more.

[olaf hart]

I found the component diagrams for the D1 and D2 engines,they use the same design heat exchanger and both use o rings.

Maybe they need to be set in a soft sealing compound before they are installed.

Seems a simple fix to go back to gaskets.

Are you reading this volvo people?

I was going to re engine with a D1, but not any more.

[Rustic Charm]

Does anyone know anything about overhauling a 2003 T turbo?

I have oil coming into the exhaust and of course the only available workshop manual is *****.

[olaf hart]

Originally Posted by tedsherrin

Does anyone know anything about overhauling a 2003 T turbo?

I have oil coming into the exhaust and of course the only available workshop manual is *****.

Have you checked the L-36 site?
It's the mother lode for old manuals.
I found a good manual there for my non turbo 2003

[Rustic Charm]

Originally Posted by olaf hart

Have you checked the L-36 site?
It's the mother lode for old manuals.
I found a good manual there for my non turbo 2003

The 2002-2003T manual is the same one. It's just not a very good, informative Manuel.

[olaf hart]

What sort of information are you after?
Diesel in exhaust is usually overloading ( ie dirty prop) or intake obstruction.

[Rustic Charm]

It's not diesel, it's oil. It's in the exhaust side and leaking out of a seal underneath it.

I have no problems getting it off the engine, but once it's off, is it a specialized job to replace seals in it? The Manuel has measuring for rotation etc, which I don't have the instruments to do that with.

[Rustic Charm]

Does anyone know if the engine mounts of a 2003T are the same in the front as the back?