Volvo D4 Oil Filter Manifold Housing Corroded/Leaking

[frothblower]

Hi All.

Has anyone else experienced/seen on their VP D4/D6 a small oil leak that at first glance appears to be coming from the right end cover as you look at the manifold that holds the 2 vertical oil filters but on further inspection/removal it is actually where the corner of the manifold has corroded away and the fixing screw on that corner holding the end plate in position is now doing nothing hence the oil now leaking out from past the O-ring in that corner.

Having had a google is appears I am not alone in this corrosion issue in the same place, there is even one for sale on ebay at the moment with the same corrosion issue. (item No. 254203102255) Hoping someone may be able to offer some advise from their past experiences but i'm hoping that this can be repaired maybe by having it welded then drill and re tapped or another solution as the Volvo price for a new manifold is eye watering. Would also like to know what causes this issue so I can try and stop it happening again in the future. Engine is a 2006 260hp with 370 hours.

The VP part number is 3584419.

I will try and post some pictures. These are of the one for sale on ebay but very similar to mine if not a tad worse.

 

[julians]

That doesn't look good. It looks like the filter housing Is made of some kind of alloy that corroded.

I have no advice, but I will check mine for similar issues. Mine is a 2006 engine, that's done 500 hours

 

[julians]

I think that area of the housing that has corroded might be in line for being dripped on by any raw water leaks from the heat exchanger end caps.

Leaks from there can also damage the starter motor.

 

[simonfraser]

yes keeping salt water away from the engine is crucial.
fix all the water leaks so you know where it is all comming from.

 

[spannerman]

I think that area of the housing that has corroded might be in line for being dripped on by any raw water leaks from the heat exchanger end caps.

Leaks from there can also damage the starter motor.

If it gets as far as the starter motor it often takes out the engine harness which is engine out to replace, we had a lot of these some years back before they did a mod for the end caps.

 

[volvopaul]

Yes an every day occurrence in my job .
Someone left there ends caps leaking for too long , this is the result .

 

[stelican]

I had a similar problem with anAD31 oil cooler, Corroded externally but went into the recess for the O ring. Successful repair by tig weld, and remachining of O ring slot and oversize O ring.

 

[oldgit]

Article in MBM or PBO some time ago about a heat exchanger ? on a Turbo 36 in far far worse condition than that. Rescued by alloy welding and lathe work by local specialist.
Total cost a few hundred,compared to VPs couple of thousand.Unfortunately cannot remember the issue number.
There is usually somebody local who can do this sort of work if you can search them out.
It helps if you have some small commercial boats nearbye such as fisherman or workboats.

 

[ozzie]

Article in MBM or PBO some time ago about a heat exchanger ? on a Turbo 36 in far far worse condition than that. Rescued by alloy welding and lathe work by local specialist.
Total cost a few hundred,compared to VPs couple of thousand.Unfortunately cannot remember the issue number.
There is usually somebody local who can do this sort of work if you can search them out.
It helps if you have some small commercial boats nearbye such as fisherman or workboats.

I have just had my second aftercooler rebuilt, and the engineer advised me both of mine need doing. Looks as if it's going to be another £3k bill. Don't think it's too bad, so going to leave it until the end of the season. They are 2009 D4 260s with 600 hours. Would be interested to here if they are repairable.

 

[Assassin]

Yes they are repairable and the limiting factor is the extent of the damage and the cost of machining.

 

[volvopaul]

Hi All.

Has anyone else experienced/seen on their VP D4/D6 a small oil leak that at first glance appears to be coming from the right end cover as you look at the manifold that holds the 2 vertical oil filters but on further inspection/removal it is actually where the corner of the manifold has corroded away and the fixing screw on that corner holding the end plate in position is now doing nothing hence the oil now leaking out from past the O-ring in that corner.

Having had a google is appears I am not alone in this corrosion issue in the same place, there is even one for sale on ebay at the moment with the same corrosion issue. (item No. 254203102255) Hoping someone may be able to offer some advise from their past experiences but i'm hoping that this can be repaired maybe by having it welded then drill and re tapped or another solution as the Volvo price for a new manifold is eye watering. Would also like to know what causes this issue so I can try and stop it happening again in the future. Engine is a 2006 260hp with 370 hours.

The VP part number is 3584419.

I will try and post some pictures. These are of the one for sale on ebay but very similar to mine if not a tad worse.

View attachment 77485View attachment 77486View attachment 77487

For sale , what as scrap ?

 

[Seastoke]

Is that the plastic end caps ,if so how much are the replacement s