Volvo MD2030 - injector parts missing

[nomadsailing]

Hi all,

We are on a sail cat with dual 1996 Volvo Penta MD2030B engines.

The starboard has a bad fuel knock in 2 cylinders (isolated by cracking injector pipes) so I pulled the injectors only to find parts missing from the manual!!! It is the injector straight into the cylinder!

The heatshield, copper packing and insert are missing as shown in the photo attached.

I then opened up the portside engine and it has all the parts as per the manual...

Does anyone have any idea why someone would install these injectors without these parts?

I am on the phone to a Volvo Penta dealer in Puerto Rico where we are to organise getting these parts but would love some expert opinion on this situation.

This boat is new to us (January) so cant provide accurate service history etc.

Cheers
Paul

[senormechanico]

Probably just another mechanic who doesn't give a damn about his work.
OT, but I found the reason for my car's anti lock brake problem.
After getting a horrible "fix" for the air conditioning problem (another long story) I found he had cut the anti lock wires to the wheel next to the AC compressor and when done, just twisted them back together. The cuts weren't even staggered. There was no crimping or soldering, just loose twisting and tape.
Any time I find electrical tape where it doesn't belong, I suspect bad workmanship. I'm usually right.



I suspect the PO or his mechanic did similar to your engine. What's a few left over pieces? Toss 'em.

[nomadsailing]

Originally Posted by senormechanico

Probably just another mechanic who doesn't give a damn about his work.
OT, but I found the reason for my car's anti lock brake problem.
After getting a horrible "fix" for the air conditioning problem (another long story) I found he had cut the anti lock wires to the wheel next to the AC compressor and when done, just twisted them back together. The cuts weren't even staggered. There was no crimping or soldering, just loose twisting and tape.
Any time I find electrical tape where it doesn't belong, I suspect bad workmanship. I'm usually right.



I suspect the PO or his mechanic did similar to your engine. What's a few left over pieces? Toss 'em.

It's the only logical explanation I can come up with! Crazy, and they wonder why it was hard to start and had a fuel knock. Looks like volvo can get the parts to me for under $200 in 3 to 5 days in Puerto Rico! not too bad. Fingers crossed the fuel knock goes away after I get the injectors rebuilt this week in Ponce.

[nhschneider]

I had a problem on my Volvo MD40A with one injector not sealing properly. I solved the problem by adding a second copper washer.

I also had a very bad but intermittent fuel knock and finally solved that problem by removing the engine and replacing it with a Beta Marine.

Fair winds and calm seas.

[jimbunyard]

Most likely due to ignorance and/or two or more people doing the work. That all three injectors are missing the same parts is telling...

[nomadsailing]

Originally Posted by nhschneider

I had a problem on my Volvo MD40A with one injector not sealing properly. I solved the problem by adding a second copper washer.

I also had a very bad but intermittent fuel knock and finally solved that problem by removing the engine and replacing it with a Beta Marine.

Fair winds and calm seas.

that's a fool proof repair for the knock. don't worry if re-powering comes up Volvo wont be on the list. Good choice on the Beta

[Compass790]

I'm very surprised it wasn't leaking at the injectors. How many hours on the engines? i'm just wondering if it was possibly an assembly error at the factory. Was there any indication they were ever removed before you did? i.e. cracked paint, spanner marks on the flats.

[nomadsailing]

Originally Posted by Compass790

I'm very surprised it wasn't leaking at the injectors. How many hours on the engines? i'm just wondering if it was possibly an assembly error at the factory. Was there any indication they were ever removed before you did? i.e. cracked paint, spanner marks on the flats.

I think they did have copper washers in them as when I removed them there was burnt up copper pieces in the cylinder I had to vacuum out so that was probably saving any leaking. ~4000hrs and I believe they had a rebuild of this engine over the years due to being difficult to start... so I think we can narrow it down to the rebuilders for the missing parts

[Compass790]

Thanks for explanation. If you get a chance please let us know if installing the missing parts solves the knocking problem. Do realise now why they didn't leak as they are screw in injectors so easy to put sealant on the threads.
good luck with getting the parts

[nomadsailing]

Originally Posted by Compass790

Thanks for explanation. If you get a chance please let us know if installing the missing parts solves the knocking problem. Do realise now why they didn't leak as they are screw in injectors so easy to put sealant on the threads.
good luck with getting the parts

Will update. Had them rebuilt for $75 each at RD Diesel Technology in Ponce, PR in 2 hours the other day! Great service and thought maybe that alone would fix it but it didn't. Trying to now save them and that engine until these new parts arrive on Monday but we are beating windward so 2 engines is a bit necessary.


Here is some injector rebuild porn for you anyway

[Compass790]

Oooh yea, sexy! Amazingly cheap for green engine repairs if they put new nozzles in them.

[Midnight Son]

The top mounted injectors had copper cups that have to be swaged in top and bottom, so 2 more tools to buy. This engine looks to have side (angle mounted) injectors but still has a cup of a different sort. Haven't seen one in the metal so far. Do not have any experience with them. So avidly following this.

Cheers

[nomadsailing]

Originally Posted by Midnight Son

The top mounted injectors had copper cups that have to be swaged in top and bottom, so 2 more tools to buy. This engine looks to have side (angle mounted) injectors but still has a cup of a different sort. Haven't seen one in the metal so far. Do not have any experience with them. So avidly following this.

Cheers

Yeah at first from reading some forums I was afraid I had that style and watched some videos with the specialised tools for pulling the copper sleeves. But this engine isn't like that.

I got the new parts today and put them in... sadly it did not fix the knock in cylinders 1 and 2

Though at least I have some confidence in the right parts existing now so better then nothing. Pics attached show the parts. It is a hard spacer then a small cup of lighter material, I thought copper but I guess steel. Then just 2 gaskets. Pictures attached.

Where to now for the fuel knock? Injector pump?

Cheers

[jimbunyard]

Can you describe the knock more fully? Does it improve when the engine warms? Doesn't seem likely, but does it 'follow' the injectors? Did the work you've already done improve the starting ability?

Certainly sounds like a pump rebuild may be in your future...

[Compass790]

Are you absolutely sure it's a fuel knock? Bit scary saying you had to vaccuum copper bits out of cylinder What's the fuel filtration system like? I'd be a little surprised if injection pump was bad at those hours. Of course bad maintenance can kill anything.
Bit of a worry tho if it's already had one rebuild & evidently a bad one at that. Assume you've done valve clearances & timing. Compression check?