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Old 16-04-2023, 23:57   #1
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Corrosion in Heat Exchanger & Exhaust Elbow

Hello Cruisers,

in our Broadblue 42, we have two Volvo Penta D2-55. After we found major corrosion on the port side exhaust elbow and heat exchanger which ultimately needed replacement, we asked the engineers to take it on the starboar side apart as well to doublecheck there (we are not on the boat atm).

Results see pictures attached, what would you recommend us? Engineer is recommending to exchange, but they always recommend to exchange everything. And whilst it would be okay to exchange the exhaust elbow, the heat exchanger would be a high-ticket item we would not want to spend this season...

So would it be valid to ask the mechanics to just clean and repair the heat exchanger? What is with the exhaust elbow?

Greetings
Timo
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Old 19-04-2023, 11:35   #2
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Re: Corrosion in Heat Exchanger & Exhaust Elbow

the whole is very sick... you will have to think about replacing (ae...)
be careful to fit good seals when reassembling ...
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Old 20-06-2024, 11:00   #3
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Re: Corrosion in Heat Exchanger & Exhaust Elbow

Could a heat exchanger repair have a chance? It is a very pricey item. Has anyone done it by welding and then machining the face of the manifold?
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Old 20-06-2024, 14:52   #4
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Re: Corrosion in Heat Exchanger & Exhaust Elbow

Yes, it can be repaired by welding and machining. Several threads here on CF about this.

It’s not unheard of on the D1&D2 series engines as well as the preceding MD 2010 - 2040 series.

My personal opinion is that it is a result of poor design exhaust elbows which direct water into the exhaust stream too close to the manifold and at a bad angle.
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Old 20-06-2024, 22:39   #5
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Re: Corrosion in Heat Exchanger & Exhaust Elbow

Quote:
Originally Posted by DougR View Post
Yes, it can be repaired by welding and machining. Several threads here on CF about this.

Its not unheard of on the D1&D2 series engines as well as the preceding MD 2010 - 2040 series.

My personal opinion is that it is a result of poor design exhaust elbows which direct water into the exhaust stream too close to the manifold and at a bad angle.
Thanks, I will look into these threads. I like your theory. The corroding part should be the less pricey elbow..
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Old 21-06-2024, 01:34   #6
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Re: Corrosion in Heat Exchanger & Exhaust Elbow

Quote:
Originally Posted by Dane View Post
Could a heat exchanger repair have a chance? It is a very pricey item. Has anyone done it by welding and then machining the face of the manifold?
yes you must remove heat exchanger and give first aluminium welder later machinist for SURFACE GRINDING & MILLING
also buy this (first what i find good price)https://www.poseidonmarine.eu/hr/pro...olvo-d2-md22-1

hi must put more aluminium to folow this line. outside down is week spot put more aluminium.
and for future every year this must be normal check,first sign rust remove wash in phosforic acid ,ultrasound cleen ,paint return.
bolt is special ask perkins dealer or order in london is main warehouse
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Old 21-06-2024, 01:42   #7
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Re: Corrosion in Heat Exchanger & Exhaust Elbow

this company i give to work huge expirency in d1-d2 exschange repair. daily working with this.
https://ive-commerce.hr/
if you don't find locally can send me i drive for this service and personal give.but you must wait minimum 1 week. lot repair
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Old 21-06-2024, 01:53   #8
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Re: Corrosion in Heat Exchanger & Exhaust Elbow

after job finish must look like this



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Old 21-06-2024, 11:09   #9
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Re: Corrosion in Heat Exchanger & Exhaust Elbow

Quote:
Originally Posted by more View Post
this company i give to work huge expirency in d1-d2 exschange repair. daily working with this.
https://ive-commerce.hr/
if you don't find locally can send me i drive for this service and personal give.but you must wait minimum 1 week. lot repair
Hi More,

Thank you for the valuable information. For sure it must be important to find an excellent welder. Very nice of you to offer to help me out. I will see what I can do in Denmark, but may well contact you :-) Thanks!
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