Volvo Penta 2003 Engine Service on Zephyr IV. I did it myself !

[@kburns4695]

Thanks very much for the clear step-through guide, just wish I'd found this video before i made all the rookie errors - i found doing the primary fuel filter the worst & lots of diesel ended up in the bilges 😢. Tip from another video: incontinence bed pads are ideal to soak up any spills.

[@davesailing]

I'm so glad it helped. I am actually thinking doing another video of the same thing and try and make it even clearer. There are bits of it that could be better. Always difficult trying to hold a camera and talk and do the work :-) Best Wishes ... Dave

[@louiseharvey-dd8po]

Hi Dave, just watched you volvo penta engine service video, best I've seen and very helpful to me. I have a Beneteau 32.5, a real novice sailor but love it. I need to learn to service my engine on my own, and your video has given me the confidence. Thanks Dave, Louise, Perth, Western Australia.

[@davesailing]

Hi Louise, I'm so glad you found the video useful. The basic service is not that difficult, just a bit messy with diesel and oil. Take your time and good luck with it. Glad you're enjoying your boat and sailing. It's a wonderful hobby.. Take care .... Dave

[@laurencevanhelsuwe3052]

I'm about to buy my first boat. Good chance it will have a Volvo Penta, so this type of video is wonderful. Have no mechanical background, but it all looks doable. Thanks for filming and sharing!

[@davesailing]

You're very welcome Laurence. I'm sure you could do the basic filter change and oil change, it's a bit messy but it gets easier every year. Highly recommend keeping a log and include details about the filters, difficulties you experience and tools you used, spanner sizes etc. Good luck with your new boat hope it all goes well... Dave

[@gingerbard2607]

For absolutely no good reason I prefer that, when I do buy a boat, it has a beta marine engine. But this has to be the clearest marine engine service tutorial I've watched. Great stuff!

[@davesailing]

Thank you for the praise, I just tried to show it as it was. Despite its age the Volvo Penta 2003 works well. I look after it like a baby, change the oil and all the bits every year and up to now it's looked after me.. Dave

[@stuartwineberg3653]

Another good one Dave. I could never stop the CAV filter leaking and I’ve binned it for a Racor clone, 30 seconds to swap the filter. My other thought is take a look at parts4engines, they do high quality substitute parts , Perkins oil and fuel filters and fleet guard CAV ones, much cheaper than Volvo. I smear a load of silicon grease on the pump shaft before refitting the impeller makes it easier to get out. Great idea to make a video from a boring routine task. Keep warm.

[@davesailing]

Thanks Stuart, who's got a nice shiny boat now? :-) She looks lovely. Ok on the alternative parts. I thought I'd try to go with proper Volvo parts and then I could relax. But this year I realised that Volvo themselves used alternative suppliers, so next year I'll probably look elsewhere. I'd seen the Parts4engines web site but just felt safer going with the Volvo bits. I'm no engine expert :-) But maybe next year. I'm always surprised the engine starts after I've finished the service :-) See you in the New Year, Have a lovely Christmas... Dave

[@AndyPidsleyAPi]

I did the same, the CAV filters are terrible things to reassemble esp in an emergency. Racor all the way.

[@StemtoSternSailing]

I'm a mechanic by trade. You did a good job, and the knowledge you poses and displays in this video is by the book. Well done. The last piece of advice you gave is no understatement. The more experienced you get the less messy it becomes. Still bring lots more rags and paper towels than you could possibly imagine you would need. Somthing fals over or slips out of your hand at the wrong moment.......... need I say more. Job well done. Beat regards from Jarle

[@davesailing]

Thank you so much Jarle, it went a bit better this year but filming it did make it more difficult, especially when my hands get a bit oily (despite the paper towel :-) and I worry about damaging the camera. The bit that didn't come out too well was bleeding the CAV filter. Despite my best efforts it started leaking diesel and I had to strip it all down and start again - and needed lots and lots and lots of paper towel :-) and I forgot that I hadn't filmed the air bleeding bit. So I fudged, when I edited it. Oh you've done the falling over bit too :-). Last year I had to move quickly and moved my foot away quickly but it was on a newspaper that a bottle of waste oil was standing on. My foot pulled the newspaper away, litre of waste oil all over the floor. One of those occasions when you need another pair of hands. It must be nice to service an engine on one of those nice stands that you see in showrooms. I'm pleased with how quickly the engine starts though. I saw a video the other day where the engine turned over 10 or more times before it fired. Zephyr IV's turns over once and it's away. Hope you have a lovely Christmas, Take Care .. Dave

[@aquamark1]

Tip to bleed fuel filters go to the last filter put some blue tak around the oil suction pump hose open bleed screw put hose on bleed screw use blue tak or amalgamation tape to make a rough seal and pump until till fuel starts flowing...enjoy

[@dreamtimesv]

Wonderfully clear, thanks

[@davesailing]

Hey glad you found it interesting. It was tricky to film, sometimes holding the camera in one hand and working with the other. I need a camera man :-)

[@ozkancaldagi7801]

Thanks for your effort.

[@davesailing]

That's very kind, glad it was useful. Thanks for watching.. Best wishes....Dave

[@tomasgoenaga7442]

Very clear!!!

[@davesailing]

Glad it was helpful! Best wishes.. Dave

[@uuugberns]

Thank you! Supper well done!

[@davesailing]

Thank you Gustavo, glad it was of some use.. Dave

[@aquamark1]

Tip put a dab of vasoline or grease to keep o ring seal up

[@nickspeller3372]

Instead of paper to catch the drips I use nappies...much more absorbent and you can jam them into areas where fluids would just run off or soak thru newspaper. Just a thought.

[@davesailing]

Hi Nick, thanks for your comment. I guess you might have young children :-) I'm doing my best to forget the nappy stage. My daughter is in her 40's now :-) But it is a good idea. Thanks ... Best Wishes .. Dave

[@nickspeller3372]

@davesailing it's just they very cheap and a great way to soak up spillages in the bilge of oil or contaminated water. I always keep a packet on the boat. They soak up a phenomenal amount of fluid too no matter how viscous. Definitely keep a packet on board.

[@nickspeller3372]

@davesailing I don't have children lol. I don't believe supermarkets check when u buy them lol

[@davesailing]

@@nickspeller3372 I Might just brave the babies and infants isle and pick up a packet :-)

[@Viljonkki]

Thank you for a very helpful video. I have exactly the same engine in my boat and wonder how I can change liquid in freshwater side where is 50% of coolant and 50% of water. Do you have any advices for that job? I found something from google but still need some more details... Thank you Dave -Tomi, Finland

[@Viljonkki]

Actually I think I just found an answer from this manual (page 25, last row). Maybe thats what I have been looking for. 🧐 avdhoeff.home.xs4all.nl/zeilen_bestanden/Volvo-Penta-Type_2001-2002-2003T_Workshop-Manual.pdf

[@davesailing]

Hi Tomi, check out my video about fixing a leaking heat exchanger on the 2003. You might well have the same connector to drain the coolant from. Best wishes Dave

[@Viljonkki]

@@davesailing I found that same connector, but couldnt get any coolant out from it. Have to figure out how it is done. - T

[@davesailing]

@@Viljonkki The outer sleeve of the connector unscrews a little and that opens the valve and lets out the coolant. I used a vacuum vessel to suck it out though when I first drained my coolant I just let it drain, but it took a long time and I couldn't get all of it out. Hope that helps :-) Dave

[@aquamark1]

TIP when doing filters you can use zip lock bags to catch fuel & oil

[@sailingeastcoast]

Hi is there an anode to change ones in a while on these engines?

[@davesailing]

Well I initially didn't think there was and then I found a couple of unused anodes in the spares kit that came with the boat and found videos showing how to change it. BUT I can't find one where I expected it to be. So now I'm just as uncertain as you. Sorry 😞... Dave

[@x9habs]

Hi dave! Im having the same problem as you do with the replacement fuel filter .. could you share me the info of the ford fuel filter youve got?? Thank you so much 😊

[@davesailing]

Hi Xavier, I suspect that there are several filters that would fit and work. The one I've got at the moment is made by Mahle, model number KC20. It fits perfectly. You can buy them online from lots of places, even Amazon. Less than £10.00. The Volvo parts list doesn't seem to have one that fits now - crazy! Please subscribe :-) Best wishes ... Dave

[@ChrisDenny28]

Behind the blue hose/behind the secondary/fine fuel filter are 2 wires coming out of a sensor in the top of the engine. What is that sensor?

[@davesailing]

Hi Chris, I think it's the engine temperature sensor. The thermostat is up there. You'll find the Vovo Penta service manual online. That should tell you for sure.

[@ChrisDenny28]

@@davesailing Thanks! I also thought it was a temp sensor, but I was surprised to see it in that location. I have a sensor that I can't identify on my 2002. It is behind the alternator and right below the thermostat. It has 2 prongs sticking off of it. I can't seem to identify it via the owner's manual or shop manual. Do you have a sensor there too?

[@davesailing]

@@ChrisDenny28 Hi Chris, I'm not sure. I'm away from the boat at the moment but will be back on board at the end of next week. I'll have a look then and get back to you... Dave

[@ronaldhill7574]

AQD40 Volvo Penta diesel with blow by --any ideas? BIG job or little job?

[@davesailing]

Hi Ronald, I'm not a diesel engineer but there are lots of youtube videos about the problem. kzbin.info/www/bejne/n6fIfppsis13fNE is a good start. If I had the problem I wouldn't tackle it but would get a qualified engineer to do the job. It usually means getting the head off so I guess I would describe it as a fairly big job. I have a good engineer contact and I asked him what problems he'd experienced with Volvo Penta engines and he immediately said, "Owners interfering with the injectors and damaging the cylinder head." I hope you can sort it out soon. ... Dave

[@JJamessssss]

Is there any anodes on the raw water side of this engine?

[@davesailing]

Hi James, to be honest, I'm not sure. However I do know that the anode on the Hull is connected to the engine, so presumably that would provide the protection.

[@AndrewJWass]

no anode@@davesailing

[@freerkottema]

If you replace the new fuel/oil filter grease the o ring with a little oil so it ll come off easier next time. Cheers

[@davesailing]

Thanks for the tip 🙂

[@George-ko8cd]

Your engine looks like it doesn't smoke at all, ours smokes alot. Any idea what could be causing it or what to check first?

[@davesailing]

Hi George, I'm not a diesel engineer but you'll find a lot of information by asking Google, "What makes Volvo Penta Diesel Engines Smoke". A lot depends on what colour the smoke is. Black usually indicates too much fuel, blocked intake filter, there's a whole list of things. Blue is the worrying one, that's usually due to engine wear and oil getting past the piston rings and burning. If it was me I would try a diesel fuel additive, which would help clean the fuel pump and injectors and valves. Maybe it would pay to talk to your local engine man 🙂 Good luck with it, let me know how you get on.

[@brusselsprouts6847]

You missed 2 of the main orings on the pre fuel filter mate The one on the bolt and the one underneath

[@davesailing]

I didn't forget them, I showed the one on the drain plug at the bottom but somehow didn't include the bit of video showing the top one.. :-( Thanks for the comment, I hope you subscribed, do take care :-)

[@brusselsprouts6847]

@@davesailing cheers mate there is 6 to change on them - drain bung - bolt oring under top washer - the 2 between the glass and the top large one - 1 beneath the top of the filter to separate the clean and dirty fuel Just giving you the heads up mate Just subscribed 👍

[@davesailing]

Thanks gor that and subscribjng😊😊

[@sailing554]

Very helpful thanks 👍🏻

[@davesailing]

You're welcome, thanks for watching.. Best wishes... Dave

[@ronaldhill7574]

Ok