Volvo Penta Injector Blow-By (Part 1 of 2) | ⛵ Sailing Britaly ⛵ [Boat Work]

[@SailingBritaly]

Thanks for watching! 🔔 SUBSCRIBE if you haven't already (It's free!) ➜ bit.ly/Subscribe⛵ Join our waiting list to get our Financial Freedom PDF, for free, here ➜ bit.ly/FinancialFreedomPDF Get a FREE PDF with over 3,500 knots & splices here ➜ bit.ly/knotsPDF Check out our 🗝️TREASURE CHEST🗝️ here ➜ bit.ly/TREASURE⛵ 🌳 Help us plant more trees! ➜ bit.ly/Britaly4770Trees Do you want Chris to help you with a technical problem, one-to-one, via videocall? Book a call here ➜ sailingbritaly.com/videocalls Comment below, we read every single one! Chris, Rossella & Emma 😊

It almost all goes over my head but it definitely made the engine seem less intimidating to hear the explanations and see it taken apart. Thanks again for very useful information! Great video! 👍

[@SailingBritaly]

Hi Janise, thank you! If this were ever to happen with a tow vehicle in a remote location the "hammer & spanner" quick fix could help to get you moving again - even though everything you need to be comfortable would be behind you anyway! Send our love to the gang! ❤️ Very best regards, Chris, Rossella & Emma 😊

[@ratusbagus]

Now this was an absolutely Ace video Chris. So many are pitched at basic, basic level. It was great to have a number of graduated in quick/difficulty solutions explained. I removed engines from junk cars with my brother when we were 16-18 and we knew nothing. Grinding valves and replacing rings, big end shells, oil rings, head gaskets and of course grinding valves with sucker sticks and paste. What fun eh? Then a life of clean soft hands in IT. So yeah I'd have a go at this. Also annealing. I remember this from school 50 that's five ohhh years ago. I did something called planishing with a gas brazier, sheet of copper, bowl of acid (remember it but not the why), a planishing hammer and a domey anvil thing in the Jaws of a vice. So remember the repetitive annealing process to make it malleable. Remember it went a dull pink. Congratulations on the olive you made BTW. Injectors.... I never hacked a diesel so don't understand injectors. But a couple of years ago, I paid about £800 to get one done (VW wanted 1200) once. The guy I phoned wouldn't do it on my drive until his expert came back off holiday. He said he'd left sheared off injectors in the head before. So I gathered there was some risk attached to what you did here? Again. I really appreciate this one Chris. Excellent production.

[@SailingBritaly]

Learning by doing is the best form of education! Injectors can be a pain to get out but it's worse on a modern car where there is very limited space to work and with lots of things getting in the way. If they were really badly stuck I'd have made a slide hammer type tool to get them out, but fortunately 10 minutes of leverage and twisting did the job. Thank you for your comment, we get a lot of motivation from comments like this. Cheers, Chris 👍

[@thomasgregory9462]

Loving the quality of moobs in this production 🤣. Joking aside a man after my own heart, you've done well.

[@SailingBritaly]

😂 I mention this in part 2. It's definitely not an attempt to be sexy, it was scorching hot and I didn't want to wreck any of my clothes. Cheers, Chris

[@Sailingon]

Your engine has the same cooling system as mine, raw water cooled with no heat exchanger. Took a couple of goes to get the right alternator belt. Great informative video, never seen the washer idea before that was ace

[@SailingBritaly]

Thank you Samantha, it's handy for re-annealing old washers too if you have to dismantle something and put it back together when spares are hard to get. Cheers, Chris

[@spelunkerd]

You made many thoughtful remarks, brilliant discussion. Although most people get into DIY repair to save money, the cash I have saved was always reinvested in tools. For those who watch, never forget that there will be an unavoidable learning curve, you are going to make mistakes that a pro would never make. The great advantage of home repair is the gratifying feeling of insight regarding how these intriguing engines work.

[@SailingBritaly]

Thank you! It's all about self-reliance for us (which I see as a form of freedom). I want to know that whatever happens on board I can deal with it without having to rely on others. That's the end goal, but of course getting to that stage is a journey in itself! Best regards, Chris 👍

[@stephenauty2402]

Mine is a 2001 so 1 cylinder, diesel leaking past the injector. Injector took ages to get out, used a slide hammer in the end. I bought a reaming tool and while I was doing it you could see it cutting the outside edge first and slowly came into the middle to finish the job , however it still leaks so I'l take it out again and fit a very thin washer. You have to make sure whatever you take out you put back in so the injector nozzle is in the correct place within the combustion chamber. I love the twin VP 2002 but alas it won't fit in my boat, it's too long.

[@shamoy1000]

Excellent instructional video. I learned a lot about a problem we're having right now.

[@johnnyandersson5622]

Did one injector sleeve with the milling tool made for this application a couple of month ago on my 2003. Have run the engine maybe a hundred hours and no leaks. It was a loud whistle at the end. :) By the way, the milling of the sleeve is NOT a quick fix, it will hold up as good as a new sleeve if you do it correctly and put the exact thickness of an injector sleeve copper compression washer.

[@SailingBritaly]

Good on you Johnny! It's a quick fix in the sense that it is less time consuming, than replacing the sleeve, but I agree that milling the sleeve is a good repair. Congratulations for fixing this issue and thank you for sharing your experience to help others. Cheers, Chris

[@henrirotthier5710]

Chris, you are a DIY genius. I try a lot myself, a but this is something I would definitely pass. Nice video tough.

[@SailingBritaly]

Hi Henri, thank you, I hope you and your family are well! Cheers, Chris 👍

[@henrirotthier5710]

@@SailingBritaly Yes Chris all is fine with us. As it was too late to leave with our sailboat, we left him in Nieuwpoort. We are now at the Côte d'Azur fill end of September with our little motorboat. If you ever come in the vicinity of Saint Raphael (Near Cannes). Just let me know. I know some nice anchorages.

[@SailingBritaly]

Hi Henri, 2020 is the year of modified plans... Have a great time in that beautiful part of the world! :-)

[@maurol.3731]

A nice video, thanks Chris. First the maintenance then the repairs to the engine should be part of the overall competence of a good skipper (always within the limits of the equipment on board). I learned a lot by often meeting "diesel specialists" who were just bad mechanics ... So, "who does it by themselves does it for three", is an Italian proverb that has accompanied me all my life! Nice work, I wait for the second part in the next video. Stay safe

[@SailingBritaly]

Hi Mauro, we might have some shared experiences in Part 2... Grazie e buon vento! Chris 👍

[@lubakaczmar3198]

Great job. Have same engine. ENJOY THE WAY YOU APPROCH THE DAY.

[@SailingBritaly]

Thank you 🙏

[@dakardad1]

The washer fab is awesome. I can hardly wait till l need to do it haha. I keep carbon build up to a min with Seafoam. Works for me.

[@SailingBritaly]

Annealing can be handy on 'old' washers too. A leaking joint can often be resealed by taking it apart, annealing the washer and reassembling. Cheers, Chris

[@StevieB_Slowbart]

Thanks for the very clear explanation.

[@bekirbayburt6157]

5:28 Preciousssss!!!! Love it, cracked me up...

[@SailingBritaly]

😊

[@dreadnoughtb3364]

I like it "first is the hammer ". Good video again.

[@SailingBritaly]

Thanks 👍

[@blakelieschke14]

Nice work mate learnt a lot with this vid. Note to self on the cover washers 👍

[@SailingBritaly]

Thanks mate! 👍

[@randyowens2717]

The food is beautiful too!

[@midgoog2]

Chris, You need to use the 50+ Suncream at a shorter interval mate. 😀😁😁😀 Cheers Eric

[@MrZachalewel]

Very useful information. Thank you!

[@SailingBritaly]

Thank you for helping us make it Zach! Very best regards, Chris, Rossella & Emma 😊

[@andysimons9226]

I just did the injectors on my old md7a. I actually had a spare engine so I reconditioned the injectors out of that. When I came to get the injectors out of the boat engine they wouldn't budge! I even ran the engine with the clamps loosened, revved the nuts off it, no joy. One of those injectors took me 15 minutes of slide hammering to get out, I had the head off, of course. She's sweet now! Bloody old diesels, bullet proof!!

[@SailingBritaly]

Good on you Andy, anything in life much more satisfying when you have challenges to overcome. Boats give a whole load of satisfaction! 😂 Cheers, Chris 👍

[@TATEXPRESSINC]

Definitely gonna subscribe to your channel

[@vxnova1]

Thanks Chris, great info

[@SailingBritaly]

Thank you for helping us make this video Richard! Very best regards, Chris, Rossella & Emma 😊

[@michaelbundy3867]

Interesting, something I need to have a look at. Mine is just a single cylinder and makes such a noise don't think I would hear Air escaping but like the idea of placing a light tissue over it and see what happens. Good to know some of those quick fix methods. I have recently put an outboard bracket on the boat and keep a little 3.5 hp in the cockpit locker. It would get me home with the tide. My little Bukh is 40 years old now and previous owner gave me the outboard for free with a bracket so might as well have a back up plan.

[@SailingBritaly]

Hi Mike, you usually see a black gunk deposit around the base of the injector before it gets to the stage where you hear combustion gas escaping. There is that big black mess of sticky goo for the gas to make its way through before it gets to the top of the cylinder head, so the black goo escaping comes before the first gas can be heard or felt. Having a back up plan is always a good idea at sea! Thank you for helping us make this video! 🌟 Very best regards, Chris, Rossella & Emma 😊

[@Spicks96]

You have a copper washer already fitted to the base of the injector Mike so it would start to wear that away first so no issues with that. Its a different set up on the Buhk. You might get some carbon build up on the very tip of the injector, thats it really. Just be careful not to lose the small injector tip cap that sits between the injector and copper washer :)

[@MayaOpperman]

Subscribed because I have the exact same engine 😁 Very impressed with the info too

[@philipgreen6332]

evening Chris, if you ever get one of those injectors that's stuck in good style, get a can of cheap coke or Pepsi, pour it on the offending area, leave overnight and it dissolves the black carbon deposits holding it in .sounds weird but it works. also you could try making a slide hammer using an old injector pipe nut welded to a small bar.

[@SailingBritaly]

👍

[@1962gms]

Hi Chris, this one is really interesting. It is always good to look at the oily bits and seeing you do it gives me more confidence to give it a go if needed. Hopefully never needed, but having at least some rudimentary knowledge is very helpful. Hope the curry was as good, it looked it 👏

[@SailingBritaly]

Thank you Gary, glad you enjoyed this. Rossella makes a very nice curry, as well as delicious Italian food. I'm getting hungry just typing this! Cheers, Chris 👍

[@lewisirvine8065]

Do you have any experiance dealing woth the penta pullstop mech? Bloody love my lill penta 2001 but damn sometimes it does not want to stop!

[@pedrom5919]

Fantastic video...as usual.

[@SailingBritaly]

Thank you Pedro 👍

[@harbourdogNL]

4:45 Smart. That's the thing about boats...you need to carry a spare boat with you...🤣

[@SailingBritaly]

👍

[@SkippySailor]

The hole made by the injector seat cutting tool looks similar to what I drilled in my mainsheet traveller car using a normal drill driver

[@winnsail31]

Very helpful video. I have a '84 VP2002 on my Dehler db2 that I recently shipped over from Germany. We have injector blow by, most noticeable during starting on cylinder one (forward one). There was a lot of black stuff, like putty (for lack of a better term), hardened glue it looks like but can be pushed around with a screwdriver. I like the idea of quick fix one, obviously, but would be interested in how it has worked for others or should I go to fix two just to get it done properly? Fix one looks like you tap with a copper tube on the injector to try to re-seat then re-tighten the nut? just to confirm. Thx (subscribed, btw. Great channel) Cheers

[@harbourdogNL]

Fascinated by your legal disclaimer! I must ask, did you run into an issue with someone or did a smart lawyer friend advise you to add this to your channel description?

[@SailingBritaly]

Never had any issues, just covering our Derrieres! 👍

[@peterhauritzjensen2559]

Hi skipper. Hope you can give me a good advice. I need to do the same job as you have done, changing the injektor sleve and get my duel nozzles spray testet, but I do have a litttle problem. I can't removerførsel my valve cover due to the screw under the decompression handle has broken. Any good advise....can I bore it out or? By the way, I'm a Flight engineer as well and have been working for the Royal Danish Airforce :) Best regards from Peter.

[@boardelia]

Hi there Chris, i was away for a while and i see now that you have great new videos, great job bro ! I have black sticky dust all over the engine compartment and I wonder if it could be engine blow-by or alternator belt friction...Any ideas on where the dust is coming from? How do I check if it's blow-by anyways ? With a flying piece of tissue ?

[@douglasprovost768]

Another great informative video.

[@SailingBritaly]

Thank you Douglas. :-)

[@kenweis7913]

I've herd that all decompression switches will leak eventually.....but I thought injectors were good

[@randyowens2717]

Beautiful! Nice job!

[@SailingBritaly]

Thank you Randy 👍

[@alidagulmini5174]

Chris, al mondo, soltanto tu potevi riuscire a fare questa riparazione in barca!

[@SailingBritaly]

Ciao! Non è vero: siamo tutti capaci se iniziamo con un po’ di testa dura! 😊 Chris p.s. Sei Alida le nostra ex vicino di barca per caso?

[@sabatieryves6536]

Très audacieux bravo !

[@SailingBritaly]

Merci boucoup Yves! 👍

[@wysiwyg2006]

Kevin of Kent marine services in Rochester is very good for marine diesels

[@340contentcreatorlab2]

Great vids, I have a 2002 as well any fixes on coolant seals/ rubber rings, particularly the special shaped ones that go to engine block and exhaust elbow?

[@SailingBritaly]

They are one of the few things from Volvo Penta which don’t cost a fortune, so if you are planning on doing work it makes sense to buy a batch of new seals. Whether you are fitting new seals, or refitting old seals, smearing some silicone grease on them will help prevent leaks. Chris

[@NoBody-me5me]

In a pinch, could you remove the injector, clean the copper sleeve, clean the injector and put a thin bead of JB Weld to fill the gap to prevent blow-by ? not the best solution because the parts would be 'welded' together, but as maybe a last resort ? Mate, love your energy and attitude, Beautiful family, Love the channel

[@SailingBritaly]

Thank you for your comment. :-) At a pinch I would be up for trying anything (which is what I did when this happened and we wanted to get our engine back). A copper washer (homemade or bought) can resist the temperatures here very well and our emergency repair lasted for 10 months with no problems (I replaced the injector sleeve as we were selling the boat and didn't want to hand it over with a temporary fix like this in place). If I needed to get the engine working again and had no better options I'd give JB Weld a try, although how well it would work (and how hard it would make removing the injector at a later date) would be all to discover. Cheers, Chris 👍

[@NoBody-me5me]

@@SailingBritaly WTF, you're selling ?

[@bootybandy]

@@NoBody-me5me I think this was the old boat and not their current one.

[@MitzvosGolem1]

May hold for a while. JB weld amazing. Belzona from UK two part putty used on nuclear power repairs also awesome. I used it to repair cylinder walls scratches in ring area on a Honda engine still runs perfect.

[@mikew7107]

Chris, I have watched a few of your engine related videos. I find them helpful. I’m rebuilding my own VP2003. I have one possible observation. I do not believe these specific injectors use a seal between the injector and tube. During my rebuild I am unable to locate a part number or any reference to this seal. I believe it seals agains the bottom of the injectors sleeve. I could be wrong but have been unable to find a different answer otherwise.

[@SailingBritaly]

Hi, there are no copper washers between the injector and sleeve in the as-designed condition. The reason I added two washers was because, despite ‘milling’ the seat area, there was still a slight leak. As I didn’t know I still had plenty of material thickness for further milling, I used copper washers to fill the imperfect mating surface in the injector sleeve seat area, which stopped the blow-by. Cheers, Chris

[@mikew7107]

Sailing Britaly Ok. Thanks. Something i just learned the special tool # for flaring the injector sleeve In the service manual is a typo. The correct # is 884823. Thought I’d pass it along.

[@SailingBritaly]

👍

[@hfoor11]

With the virus and everything else that's happening in the world, I was wondering how Rossella and Emma were and if they were going to rejoin you in the future? If you covered this before and I missed it I apologize for bringing it up again.

[@SailingBritaly]

Hi Harold, the three of us are together, thank goodness. Planning ahead appears to be impossible in 2020, so we are just going with the flow... Chris, Rossella & Emma

[@syexplorarconmigo8853]

I understand you’ve / are selling this boat-- but I wondered if your mechanic is going to perform a quick service on the two injectors since they were super gummed up with piles and piles of carbon build up??

[@SailingBritaly]

Hi there, I cleaned them up as best I could and the engine ran nicely afterwards. (I wouldn’t have paid the diesel specialist clean them as they were the ones who introduced dirt into an injector after I had brought the block to them with the injector ports ‘capped off’ with paper, and I don’t like to reward people for things like that.) Cheers, Chris 👍

[@harryderbyshire1030]

Hi Chris I've got the same engine as you in my mirage 2700 .I've just rebleed the whole engine and turned it over quite a few times but it won't start .do you know of any bleeding issues or anything that can help it start other than the cold start procedure. Cheers

[@SailingBritaly]

I’d go through the fuel supply methodically: make sure there are no blockages from sludge (fuel pick-up in tank, filters, fuel lines), bleed all parts of the system with whatever fuel pump you have - whether that be a 12v fuel pump or the hand-operated lift pump, and get air free diesel out of all bleed points and fittings. Then try again. Buon lavoro! Chris

[@louwilliams8528]

Question , my experience is with gas/ petrol engines. Going to the work to pull the head wouldn’t be wise to service the valves and check the head surface at the same time?

[@SailingBritaly]

I could have done that Lou, but I knew everything was fine apart from this injector sleeve. The engine had been running sweet for ages since my initial repair. I'm not saying you're wrong - there is definitely a case to be made for doing that - but where do you stop... Do you paint the head? If you're painting the head would it not be wise to also paint the block?... and so on... We had a baby on the way and had bought another boat in the UK (which needed plenty of work), so I just wanted to replace this injector sleeve so I could hand the boat over to her new owner with a clear conscience. Cheers, Chris

[@syexplorarconmigo8853]

@@SailingBritaly -- bravo sir... Hope that effort / courtesy comes back to you 10 fold sir... 🙏🙏

[@richardwasilkowski7355]

Hi Chris, what engine do you have, is it a md22l ?

[@SailingBritaly]

Hi Richard, this was a 2002 and we have a 2003 on Britaly. Cheers, Chris

[@richardwasilkowski7355]

@@SailingBritaly thanks Chris. Any tips on removing injectors from an aluminium head?

[@mozismobile]

Part of the price difference is the idiot allowance - if you ring up and say "the doohickey on the big lump thing is leaking I think" they have to prepare for the tech being dumped into a pile of loose engine parts and expected to make it run like new. The flip side is that if you say "come out and replace one injector sleeve" that is *exactly* what you will get. A fast, efficient replacement of that exact thing. If you're wrong about the problem that's on you. If the tech decides to helpfully point out some other problem that's a gift that you can't expect or demand.

[@SailingBritaly]

I'm happy to take on the extra responsibility with things like this but, as always, it's a question of personal preference. Cheers, Chris

[@mozismobile]

oh, very much so and that's what I usually do. I was just trying to explain a little more about why that price difference exists.

[@SailingBritaly]

👍

[@steve0680657]

Also couldn't the exhaust fumes poison the air in the boat?

[@SailingBritaly]

Yes it's not nice, or healthy, to breath in combustion gases.

[@backthebadge4009]

Not a criticism...just so I understand the process better. Did the head need to come off for the diesel tech to reseat the bad injector if he has the right tools? If no (the head didn’t need to come off) then why didn’t you just have him do that? Did you replace all the injector sleeves since you went to all the work to take the head out? If one went bad good chance the others are close behind to fail, right? Sometimes on big items like this I like to let the tech do it, because he owns it if it goes wrong. When you do part of the disassembly and it goes wrong, he can say its on the stuff you did, not him that caused the repair not to work. (Basically you goofed it, so no recourse).

[@SailingBritaly]

Hi there, I could have cut a new seat in the injector sleeve with the head in place but I only saw how much scope I had to do this once I received the new injector sleeve and saw how just thick the copper is (this is very difficult to determine with the sleeve in place in the head). I cover more about this in part 2, but there would have been plenty of material there to cut a new seat, and ours wasn't 'too far gone' as it had seemed to me at the time. The other injector sleeve was still perfectly fine so I didn't get it replaced - we were selling the boat and I wanted to be able to sell it without telling someone "There's a temporary fix on one of the injectors, but don't worry it's been fine since I added two homemeade copper washers." I wanted this problem fixed, without going down the "While I'm here, why don't we do this, and this, and this" route. I have a tendency of wanting to do everything myself. If I could have got the special tools without too long of a wait I'd have replaced the injector sleeve myself too. I was happy to take any problems on - all I wanted was the injector sleeve replacing. I understand why others would prefer to let a tech take on the responsibility for anything which goes wrong, in my case I was happy to own it. Cheers, Chris

[@backthebadge4009]

Sailing Britaly Thanks Chris...that clears it up

[@sea4see]

Grande!!

[@SailingBritaly]

Grazie! 🌅⛵️👍

[@MathysWalma]

Looked like a tight space to be working in. Hopefully you didn't bust your knuckles while taking it apart.

[@SailingBritaly]

Hi Mathijs, there is lots of room in here compared to when I used to work as a technician on aircraft. Sometimes you would have your hands through two tiny access panels in different places and you had to complete a task requiring manual dexterity whilst working completely by feel as you couldn't get your head in to see what you were doing even before you started to squeeze your arms in. This is easy by comparison! Cheers, Chris

[@robertglover1271]

Where do I find part two Bob

[@SailingBritaly]

I’m editing it now Bob. It will be on Patreon shortly and here on KZbin a few days later. Cheers, Chris

[@tomadams9155]

Is your winch still OK 🤣

[@wysiwyg2006]

That's why he got a new boat, the which had taken a knock and he was fed up of the old engine 🙉

[@whispersailing3488]

Please please don’t use your winch as an anvil!!!

[@JonMadsen70]

:)

[@SailingBritaly]

😊🌟😊