A reported coolant leak turned out to be a break in the heat exchanger - the piece onto which the cap is fastened broke off the exchanger itself. Engine is Volvo-Penta MD-2030 (3-cyl diesel). I think the center part sheared (but don't know how). The copper liner in the exchanger appears to be replaceable (?) Is this repairable - or do I require a new heat exchanger?
HELP! Heat Exchanger failure - broken metal joint
- Thread starter Ken Johnson
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More info on failure
There is a brass or copper fitting, pressed into the cast heat exchanger. This is the part that has the overflow tube attachment point, and onto which the "radiator cap" is attached. It is comparatively thin metal, and cooper color. This is the part that broke - not the cast iron heat exchanger housing. I checked the coolant mixture - protection good to below -20, and with that mild winter - no way freezing had anything to do with it. I'll try Vosbury on Monday - when they are open.
There is a brass or copper fitting, pressed into the cast heat exchanger. This is the part that has the overflow tube attachment point, and onto which the "radiator cap" is attached. It is comparatively thin metal, and cooper color. This is the part that broke - not the cast iron heat exchanger housing. I checked the coolant mixture - protection good to below -20, and with that mild winter - no way freezing had anything to do with it. I'll try Vosbury on Monday - when they are open.
Please Update Us
Ken, Sorry I can't offer any help with your problem, however, I am sure a lot of us would like to hear the outcome to your problem. Please let us know what was required to repair your engine. Thanks, Tom
Ken, Sorry I can't offer any help with your problem, however, I am sure a lot of us would like to hear the outcome to your problem. Please let us know what was required to repair your engine. Thanks, Tom
Heat Exchanger Problem
Ken I also have the same motor (but without the expansion tank) on a Bavaria 34. I have not heard of the problem, but would be interested in you you finished up fixing it. Bill
Ken I also have the same motor (but without the expansion tank) on a Bavaria 34. I have not heard of the problem, but would be interested in you you finished up fixing it. Bill
New Heat Exchanger going in this week
The Heat exchanger will be replaced - including the core (or element). The original failure is not repairable because the copper fitting was sheared off. Also, upon removal of the exchanger, it became clear that raw water had entered the system and caused corrosion, and damage to the starter and the alternator, so those parts will be replaced as well, and we suspect a failure in the exchanger element was the original cause. The engine has less than 300 hrs, and these parts were never been opened or disassembled, prior to this spring. With the repairs completed, the engine will be essentially new again. The repairs are being done by an authorized Volvo repair center - Outstanding Marine (Eastern Shore, MD) with consultation from Vosbury Marine (Annapolis), and Volvo-Penta. VERY expensive!! Thank you all who responded here, and off-forum. - Ken
The Heat exchanger will be replaced - including the core (or element). The original failure is not repairable because the copper fitting was sheared off. Also, upon removal of the exchanger, it became clear that raw water had entered the system and caused corrosion, and damage to the starter and the alternator, so those parts will be replaced as well, and we suspect a failure in the exchanger element was the original cause. The engine has less than 300 hrs, and these parts were never been opened or disassembled, prior to this spring. With the repairs completed, the engine will be essentially new again. The repairs are being done by an authorized Volvo repair center - Outstanding Marine (Eastern Shore, MD) with consultation from Vosbury Marine (Annapolis), and Volvo-Penta. VERY expensive!! Thank you all who responded here, and off-forum. - Ken
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