I am experiencing a bad injector on my Volvo 2002. Had decided to pull both and have them serviced. The forward one came out relatively easy. But the aft one is not budging.
Here is what I surmise. The mixing elbow sits right next to this injector. It did have a leak. I believe that salt water seeped down into the injector sleeve and has frozen the injector in place. I have been socking with blaster and pounding for 2 days to no avail.
Looks Like I will have to pull the head to remove.
My biggest concern is the sleeve. Will it need to be replaced, since there is more than likely corrosion in there? Or can I just remove the head, drive out the injector, then have it rebuilt?
Gary,
I had same injector issues on JUNESSA. bad news for the Volvo 2002… The injector sleeves are a very poor design (as far as removing them). I pulled the head because the sleeves would not come out. I took it to our friendly Volvo dealer for a valve job and to replace all three sleeves.
The dealer did the valve job but farmed out the sleeve job to a machine shop. It took too different machine shops to remove the sleeves. The problem is in the design… They has to drill out the flared tips and use special tool to pull the sleeves. One sleeve came out “easy”, one “took 5 hours of labor and gave up” then sent to another shop to work their magic. The shops broke two of the special pullers. Major pain in the butt!!
The second problem… Volvo has numerous sleeve sizes. The dealer received the wrong size sleeves for my head. More waiting. Eventually they got it right at around $1800 bucks. ;(
Thanks Rick,
Looked up the cost of a head exchange with sleeves etc. Cost $1500. Will talk to my diesel guru. Maybe just go that route and be done with it.
I forgot to mention, that was my other options… Sort of!
I was working with the Volvo dealer to find a complete head in the supply system, but two years ago, there were zero available. :(. So I had to hope and pray the machine shop didn’t crack my head.
I had to leave the rebuilt head, coated with WD-40, in a plastic bag for almost 6-months while I was overseas. Talk about a puzzle to put the motor back to gether from memory…It was supposed to take only ONE WEEK to tear down, get a valve job and put back together…who knew!
Next motor problem and the 'ol Volvo is getting yanked out and converting to electric.
That is too funny Rick, I have been looking at electric myself!
Besides stainless steel I am now (actually I did a long time ago) adding internal combustion engines to my most hated list for boats.
Got a good heads up regarding filter changes. Talking to an experienced friend. Said most injector clogs happen after a primary filter change. Any little piece of dust, paint chip etc can get into the primary filter and go directly to the injector clogging it. Recommended surgical environment for filter change. Guess what? my injector clog happened right after filter change. Read on another forum to fill primary filter with fuel so to speed up fuel priming. NOT a good idea!
It’s sad Rick, I had just finished a complete rebuild of my drive train with the engine out of the boat. Got her all painted up nice clean and serviced. See pic. now I am wrenching on her and she won’t look as pretty now…after all my motto is:
If you can’t sail good, you should at least look good!
Hi Gary, sorry to hear of your Volvo engine problem, but I don’t know of a fix to it.
My used BCC came with a 2002 Volvo, and right from the start it began giving me problems, not to mention the high prices on replacement parts.
I was able to swap out that Volvo for a Yanmar 3GM30F, and sold that Volvo at the once a year Minnies’ Swap Meet, sometime later.
I did find out that prices on new Yanmar engines vary from place to place, and I found mine for $ 5 K in Oregon, circa 1993 .
The Yanmar now has 2600 hrs on it, and so far it has been v reliable. I did purchase it thinking that most of the charter boat fleets uses these engines, so I surmized that parts would be available in all the exotic cruising locations.
Well it seems the injector is the least of my problems now. I had front seal replaced by the yard mechanic. He forgot to tighten the bolts on the cover for the oil pump. So in the process of trying to start the engine, there was no oil pumping to the engine. We had a cooling water issue on start up, so the engine was started at least 20+ times. Finally we had it running for a couple mintues before I realized I had no oil pressure.
Just received an oil anlyisis which confirms I did major damage to the engine.
Hi Gary, when I was in N Z , B of I , Opua , we were scheduled to go sailing with an old friend of your’s , Doug Schmuck, BCC Puffin, Totara Hill farm ,
I remember Doug! if you hear from him again say hi for me.
We will probably still go sailing, just no over night trips as Shanti is engine dependent for most of her electric and reefer.
Negotiating with mechanic to have him rebuild engine now. Also trying to find out how far the last rebuild went. If they went the full .5 mm over on the pistons, shes not rebuildable anymore.
If I had my way about it, I would rip that sucker out and fiberglass up the aperture like I did with Angelsea. only problem with that is it kills the resale value.
