Volvo 2003 - heat exchanger

Gwylan

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We have a 2003, '88 vintage and the heat exchanger needs replacing. Having seen the price of a new replacement think in the right hands capable of being repaired.
Just not my hands for this level of job

Anyone got any recommendations for possible workshop on south coast Kent - Sussex?

Or clone parts makers?

Have found starter motor at half the VP price!
 

Gwylan

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Looks a good lateral solution.
Just have to find somewhere to put it - the present one is neatly plumbed with those 'mickey mouse' Volvo press on fittings.
And mounted onto the engine block.
 
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Looks a good lateral solution.
Just have to find somewhere to put it - the present one is neatly plumbed with those 'mickey mouse' Volvo press on fittings.
And mounted onto the engine block.

You'll also have to find an alternative exhaust manifold.

I have the same problem. Let me know if you find a solution.
 

philip_stevens

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I had to replace mine last year as dezincification had made it beyond repair. The cheapest solution and price was for a complete conversion kit and from Keyparts.

The complete conversion kit was cheaper than the exchanger by itself.

As it is a VP, there is no clone made to fit where it is situated - I even tried the USA. VP patent/copyright applies.

While you are at it, check the exhaust elbow for a build-up of burnt salt.
 

Sans Bateau

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Gwylan

What makes you think that the heat exchanger needs replacing? I ask because I believe mine is going to need replacing. If there are enough of us we might be able to get a engineering company to do a production run!:D (joking)
 

Gwylan

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I love this site, it really does turn up some good stuff when you really need help.

This all started when the starter failed to do the necessary.

Those famous Volvo water joints with the rubber bush/gasket thingie meant there was always a drip somewhere.

Well, the core is fine but.... always a but. The rod that passes through the middle of the core and holds the 2 end plates on 'failed' when the end plates were removed with a lack of WD40 and a surplus of enthusiasm.

Then things got really bad and beyond my garage work bench.

The plan is to drill out the ends of the 'rod' from the centre of the core and tap that and then be able to bolt on the end plates. But it is all a bit unsatisfactory and prone to drip salt water over the starter anyway - hence my need to replace the starter.

But I think this needs someone who knows what they are doing or has some kit with a little more precision that me and my Black & Decker drill - my life might depend on this functioning properly.

Then I plan to get some pipe soldered into the end plates and then I can connect flexible hose rather than the Volvo arrangement.

Plan B is for the Bowman combined heat exchanger and heater tank that looks a very good idea and reasonable value to give me a whole new approach to the thing.

Oh and the engine needs a repaint where the hot salty water has been quietly eating everything away - any clues on that? Prep, material etc?
 

scottie

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To late now but the leaky pipes are likely to be caused by the pipes being pulled appart without loosening the other end this misshapes the pipe which does not seal again

The fresh water conv kit was a good financial option especially if you could sell the water pump and you would get new pipes that would fit

Watch when you rebuild the exchanger that the gaskets and end caps are fitted correct way as the water should pass 4 ways
 

Gwylan

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Probably right - hanging upside down in the cockpit locker trying to get the damn thing out is not my idea of fun.

So I may be culpable - but the Volvo version seems a bit too idiosyncratic.

Finding somewhere suitable to install the new heat exchanger is the next challenge.
 

Slowtack

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Took my 25 year old unit apart last winter to clean and replace rubber seals etc. Was impressed at the heay duty construction and lack of any significant deterioration. Try one of the rebuild specialists who might have a spare or advertise on the wanted site. Must be a lot of these lying idle.
 
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