Volvo Penta KAD42 1995 Build

[Wetsoundsnz]

Hi all,

I have been reading bits and peices on this forum for the last 2-3years.
Been Plenty of Great reading and now i am here just to put my story and hopefully get some ideas on my issues at hand.

A Little bit of History, I am Stewart, From New Zealand and i am 26 Years old, have been cruising since i was 13 with my
parents on our 32 Foot Genesis 320 Tournament powered by a Volvo Penta KAD42.
The boat used to be kept on a Marina birth when we used it every other weekend, our Family has grown and lots of going
ons have happen and the boat has been semi neglected over the last 4-5 years.
I my self have been hauling it out and keeping in a non rotting order.

November 2014 i pulled the boat to anti foul, checked the leg oil and put her back on the water.
Did a few short trips on her, then had an evening cruise just before New Years put the leg up as i thought
there was a vibration coming from the Props. Turns out it was just the engine cover rubbing on the Motor.
We broke the Steering Fork on the DP Drive, and got towed home by the coast guard.

So the boat has been out of the water since the end of last year, I took the top box out, removed the
steering fork and then removed the engine to get at the top nylon bush in the Mounting bracket.
Decided the Motor needed a tidy up, had a small amount of salt water corrosion from water trickling down the block from
the bad seals on the Motor Covers.

So i have cleaned the motor up, Cleaned the After cooler which was covered in Blowby Residue from the Blow By being in the
Air-filter box. I am going to make a Catch can, as i can see this causing a huge decrease in after cooler efficiency .
Cleaned the oil cooler, and Heat Exchange out, while doing this i have had to undo a few of the nuts holding the Exhaust
manifold onto the block.

Today i received all the new parts that i was going to apply to the motor, Oil Cooler Seals, Raw Water pump Drive Rubber,
Most of the Front bearings, water pump etc.

The Oil sump, was looking pretty shabby so i pulled this off and it had nearly rusted through, in doing so i found the worst thing ever
Coolant water in my sump i went from almost getting this ready to go back in the boat to now wondering what to do next.
I thought, ive come this far, i know my mechanic is coming to pressure test the Motor tomorrow morning but im going to ask on YBW.com.
So here i am.

The water is not mixed with the oil, into a sludge like one would expect (It can not have happen while running), so i am guessing that the
Nuts i had undone on the Exhaust Manifold have managed to alter the seal to the block or something and has let water into the combustion
chambers over the past 2 weeks while i have been working on the motor.

Looking up from where the sump is, it looks like every cylinder has had water in it And One Piston looks like it is coming apart.
I turned the engine over by hand and the water water hisses out around the rings and drips out.
On the Exhaust Strokes you can hear the air pushing out through the Turbo. Turbo by the way is Basically Brand new.



So should i wait for the compression test or should i just get into it?

IE Remove the Supercharge, Remove the Turbo to Aftercooler Pipe, Remove Exhaust Manifold, What do i take off on the Injection side???
Then i guess its just head bolts and lift her off? Any Pointers?
I was thinking of Videoing this an putting it up on You tube.

Any Information or other things to look at would be very much appreciated.

BOAT - But Only Another Thousand
I understand that mechanically things that sit in salt water need to be used otherwise they deteriorate
I plan on getting the boat used and sold as i can not afford to run this vessel.
But we can't afford not to fix it.

Has anyone used Non Genuine Liners and Pistons?, i was going to leave the Bearings etc alone as, not broken so why replace.


Thank you in advance

 

[Jurgen]

bump,

sorry cant help but hopefully someone will be along who can.

Good luck & Welcome

 

[Wetsoundsnz]

Yeah it killed my day yesterday. Hopefully today we can move forward and get this green slim back into order.

 

[rafiki_]

VolvoPaul is the resident expert on these things. If he does not see the thread, then try a private message. Oh, and a warm welcome to the forum too.

 

[Wetsoundsnz]

Right, So Mechanic has just left.
He didn't believe what i had told him over the phone.
He is guessing Cracked Linings...... SOOOoooo

This looks like the plan of attack, Supercharger off Manifold, Exhaust Manifold off, Injector Piping off, Aftercooler off, Loosen Cam and Lifters Evenly i think, then Head bolts out and head off.

Any Tips here of disassemble are very welcome!

Anyone keen on pictures and step by step?

 

[dragoon]

Sounds very much a guess to me - why does he think the piston linings have cracked, apart from the evidence of coolant? I think i would want more evidence before stripping the whole engine.

Did you take the injectors out, and are they the kind n the KAD 42 that can leak coolant into the chambers when removed?

Looking here someone else had the same problem, but you need to be a member to get the full thread -
http://boatdiesel.com/Forums/index.cfm?CFAPP=6&Forum_ID=83&Thread_ID=36437

Hope you get it resolved. Doesnt sound like a lot of fun, but im sure you'll get there. Please keep us informed of progress.

Cheere Paul

 

[dragoon]

...and agree with Rafiki, VolvoPaul is the man to get some input from if poss....

 

[Wetsoundsnz]

So the injectors are not out of the head nor are they touched.
There looks to be coolant leaking out of one or more cylinders as they all have rust stains

What else can I do to diagnose?

We were going to pressure test but we don't see much point as the water has got in there from the top or the sides.

I'm guessing it should be pretty evident?

 

[dragoon]

Okay, that's one possible cause eliminated.

Agreed that you appear to have liquid running out of the cylinders, but it doesn't mean the liners are cracked. I took the liner out of one of my engines, and they are a significant lump of metal, so can't see how one could crack without some very significant physical effect, let alone several of them.

Are you sure it's coolant, and not just water (sea of fresh)? Has any of the work you've done involved the potential for water to back fill from the exhaust/turbo - for example, when cleaning down with a hose?

Is it also possible that the water got into the sump through some other way, and movement / tipping ? of the engine has led the coolant to find it's way to splash onto the bottom of the liners?

Also, what's the weather like in NZ? Has the engine been subject to any heavy frosts?

Cheers,
Paul

 

[scubaman]

Just a quick note, those engines are known for head gasket problems. The design was improved on later models (43, 44) but I'm told was definitely an achille's heel in a 42.

 

[volvopaul]

Hi , it's either a cracked exhaust manifold thants allowed coolant back into the cylinder that had there exhaust valves open at the time it was stood or the liner seals have failed allowing coolant by. Before you strip the engine , remove the sump and pressure test the closed system .

 

[Wetsoundsnz]

Ahhhh i Knew i should have listen to myself and we should have pressure tested it yesterday.

Thanks Paul!

I have now got the Exhaust Manifold off, (I came into work early this morning) Pulling everything off carefully, marking everything and blocking Oil galleries and sealing off pipe work.
Paul is there a Sequence for taking the Rocker/Headbolts out?

So here is looking down:
Number 1

Number 2

Number 3

Number 4

Number 5

Number 6

Looking into the Exhaust Manifold, it looks like the water has been getting pushed out and that it is fairly recent but in small quantities.
Some are worse than others as you can see above.
Please not where the Specs of water are, is on the tops side of a the manifold not the bottom, the inside of the exhaust manifold was not wet.
A couple of the Valve stems look buggered Green Can of Worms

 

[volvopaul]

Looking at your pics the exhaust gasket to head are leaking coolant, a common problem. I've got two kad 42 heads off at the moment because there leaking coolant when running. I'd say inside the manifold the pics are showing corrosion because they have been stood with moisture, I doubt if you had the correct strength of antifreeze mix you would see that so id check it's not sea water that has entered through the exhaust elbow. Has the boat been tipped at such an angle on transport or crane to allow this? Or has it been on a mooring in a swell whereby it can syphon back?
The block pic shows you have a coolant leak down the side of the block so take the head off.
Despite what it says in the manual say have the head skimmed if only a few thou off to clean it up.

 

[Wetsoundsnz]

Looking at your pics the exhaust gasket to head are leaking coolant, a common problem. I've got two kad 42 heads off at the moment because there leaking coolant when running. I'd say inside the manifold the pics are showing corrosion because they have been stood with moisture, I doubt if you had the correct strength of antifreeze mix you would see that so id check it's not sea water that has entered through the exhaust elbow. Has the boat been tipped at such an angle on transport or crane to allow this? Or has it been on a mooring in a swell whereby it can syphon back?
The block pic shows you have a coolant leak down the side of the block so take the head off.
Despite what it says in the manual say have the head skimmed if only a few thou off to clean it up.

Yeah that's what i thought to, but that was a big part also of why i took the motor out to clean that up as water had been leaking through the Engine room doors onto the Injectors and running down the back of the head. I will take that on board.

But im guessing your looking up by number 1/2?

I am wondering if the Antifreeze was at the right strength, i am really starting to look at our old mechanic, as there seems to be a lack of grease/Antiseize or some sort of lock tight on all bolts and nuts.
And the weak looking antifreeze.

The mooring the boat is on is up the harbor and in a sheltered spot so i think that siphoning back in would not be likely?

I don't have a manual but would welcome your opinion on how to remove the Cam bolts etc?