Volvo Penta TAMD61A turbo charger reconditioning

[jms28]

Hi all,

Last summer we discovered that buildup of soot and carbon in the turbos of our Volvo Penta TAMD61A engines prevented the turbines from turning, which obviously resulted in immense performance issues on our Cranchi Mediterranee 40 (*1990). As this was unfortunately only discovered once the boat was already back in the water and just as we were ready to start our long anticipated holidays (in Greece), we undertook a last-minute "repair" with hammer and screwdriver to free the turbines as good as possible. A compromise, of course.

This seemed to have worked relatively well, albeit a decrease in the performance still being fairly obvious during the holidays. However, when we came back later in the summer for another trip the turbos seemed to have stuck completely again.

Annoyingly I can't find the pictures I took of the inside during the "repair", but it looked quite similar to THIS PICTURE from an AWESOME ARTICLE on this topic I found online.

I'm currently in the process of identifying facilities in Greece that might be able to provide a similar overhaul service as the one in the above article (I'm sure some of you are already wishing me the best of luck here haha...), but I was wondering if people here have encountered similar issues on their boat and could share their experience? Ideally of course, with the Volvo Penta TAMD61A engines and in Greece. But any input here would be of great help

I'm currently also in the process of identifying the exact turbo model that was installed here (Borg Warner KKK K27 maybe?) to see what replacements would cost. Because I can imagine a complete overhaul wont come in cheap either, so we might as well order completely new ones. But again, still weighing the best options here and your input would be highly appreciated!

I assume this buildup is due to a mixture of impure diesel, the boat not being used as regularly as it probably should be, and, of course, the age.

Thanks in advance,
J

 

[jrudge]

Are you sure it does not just need cleaning.

The wear issues with turbos are either worn vanes so too big a gap or shot bearings.

Oven cleaner removes carbon

 

[vas]

just soot and carbon built up alone, or a bit of rust as well?
Engines are original items on the cranchi or is it a repower?
Where in Greece is your boat?
a few pic of engine install/pics of the turbo exhaust side would be helpful.

I'm asking as I had to go through this process 4-5yrs ago, turbo was stuck solid. Cost iirc was 250euro to fix (not perfectly but don't care)
check this thread if you want http://www.ybw.com/forums/showthread.php?293031-port-engine-not-revving-as-much-as-strbrd

V.

 

[jms28]

Thanks for your replies all.

Just to update here: I bought brand new turbos at approx. 1,000.00€ each (incl. VAT) from STK Turbo in Germany :encouragement:

Installed in spring and tested this summer: 26kts top speed, which I'm quite happy with. Can definitely recommend this reliable and friendly suplier!

Best

 

[Tvahcic]

Hello, I have an upcoming turbo replacement, same boat and engines. I was hoping you could share long term experience on STK Turbos. How have they been holding up. thx T

 

[QBhoy]

Hi. Just recently replaced two turbos on the 61’s. One had failed similar to yours, but damaged the housing. Sent it away to AET turbos. Incredible service.
the other I replaced for hood measure. Much cheaper because they could use the casing again and just required an overhaul.
Best get them sent away asap. You could end up with shrapnel through your engine. That would be a whole lot worse !

 

[Scubadoo]

I can recommend Turbo Dynamics, they refurbished my turbo earlier this year and since then it's been performing as expected, excellent customer service and the guy I spoke to was very informative and helpful.

 

[PeterBoater]

I found Turbo Developmemts in Uxbridge very good this year Turbo Developments - Turbo Remanufacture - Reconditioned Turbochargers - Turbo Repairs

 

[ElJames]

You all mention a turbo problem but not said what could have been the possible cause for the turbo to have the problem
1/ is the oil of good quality and clean
2/very important when was the aftercooler last removed and cleaned the air filter might have been changed but that will not mean the cooler is kept clean oil fumes from the engine are also sucked in here so you cannot check without removal.A few years ago I had 61s they just started to wisp smoke which stopped after I had cleaned the aftercoolers
good luck the starboard one was the pig to remove

 

[DavidJ]

You all mention a turbo problem but not said what could have been the possible cause for the turbo to have the problem
1/ is the oil of good quality and clean
2/very important when was the aftercooler last removed and cleaned the air filter might have been changed but that will not mean the cooler is kept clean oil fumes from the engine are also sucked in here so you cannot check without removal.A few years ago I had 61s they just started to wisp smoke which stopped after I had cleaned the aftercoolers
good luck the starboard one was the pig to remove

For me with KAD43’s the cause was erosion from close proximity to salt water on the outlet side. My boat is 20 yrs old with only 500 hours. I diy replaced them a couple of years back.

 

[Tvahcic]

Hi, thank you for some great contacts. This will definitely be useful.

 

[jms28]

Hi,

I am back

Siutation:

1. Starboard engine wont go above 2000rpms and turbo pressure appears too low
2. Portside going up to approx. 2200-2400rpms but ofc slowed down by starboard side
3. Hence, I can only go at about 2000rpms and 10-15kts max.

History:

1. In 2019, I replaced both turbos with brand new BorgWarners as the old ones were badly corroded and constantly stuck after nearly 30 years of use (see above)
2. First year the performance was good but current issues persists more or less since 2021 (boat used seasonally during the summer only)
3. I was battling a bad diesel bug infection in the meantime, which was resolved this year by removing and cleaning tanks, as well as replacing filters
4. While engines now run reliably at least, performance is still lacking and issue has not been resolved by fixing the diesel bug infection (deceived us into thinking this might be the main issue)
5. Last year and at beginning of this season, I realized that both turbos were stuck again and also showed signs of corrosion, soot and salt buildup
6. Last year and this year we cleaned them manually so that the turbines turn again at least

Why I believe the turbo is the source of the problem?

1. Yesterday I took a test ride with a local mechanic
2. He checked the line to the fuel pump and established low boost pressure
3. He then connected a compressor manually to the fuel pump to see if there would be a boost - and there was!
4. He concluded that the issue is somehwere between turbos and intercooler on the way to the fuel pump
5. Also worth noting: fuel pumps were serviced a few years ago and brand new K&N open air filters fitted this summer

Main conclusions & questions:

1. The mechanic suggested to remove the starboard turbo and to bring to a local specialist for testing and taking measurements. Fair enough.
2. But the main elephant in the room for me: how come the turbos potentially need servicing after such a short time of use? Fitted 2019, no usage until 2021 (Corona) which is when the issue appeared for the first time and persists until this day. And how come there's so much corrosion, soot and salt buildup? One wise commenter asked this above - wish I had checked in earlier
3. I read about the flawed elbow pipe of the VP TAMD 61A, which is build horizontally to the turbo and w/o any decline. Is that the source of my problem? Do I need to modify them in any way to protect the turbos going forward? Keen to get this sorted BEFORE I service the turbo(s), just to have the same issue next year again

Hope the above makes sense. Any input would be much appreciated!

Thanks in advance,

Mike

 

[kawasake]

Hi Mike
Well, that elephant needs to bugger off!
Had similar problems with poor and erratic performance with our TAMD 60 C’s
The fuel system was our ‘elephant’ but during the fault finding episode I changed the crankcase filters
After cleaning the Turbos
Did about 100 hours and checked them to find them still clean
In fact ( probably wish I hadn’t said this now!) our Turbos have never given a problem
Even though the previous owners probably never went above 1400 RPM whilst using the boat ‘inland’ for 6 years or more!
I’m not too sure but at 2000 RPM are the turbos not ‘coming in’ by then?
Our snag , we’ll one of them
Was a faulty ( not seating properly ) fuel line fitting at the pre filters!
Yep, I would say your turbos should not have failed/ ‘sooted up’ in such a short space of time!
Just some thoughts Mike
Good luck!

 

[volvopaul]

Hi,

I am back

Siutation:

1. Starboard engine wont go above 2000rpms and turbo pressure appears too low
2. Portside going up to approx. 2200-2400rpms but ofc slowed down by starboard side
3. Hence, I can only go at about 2000rpms and 10-15kts max.

History:

1. In 2019, I replaced both turbos with brand new BorgWarners as the old ones were badly corroded and constantly stuck after nearly 30 years of use (see above)
2. First year the performance was good but current issues persists more or less since 2021 (boat used seasonally during the summer only)
3. I was battling a bad diesel bug infection in the meantime, which was resolved this year by removing and cleaning tanks, as well as replacing filters
4. While engines now run reliably at least, performance is still lacking and issue has not been resolved by fixing the diesel bug infection (deceived us into thinking this might be the main issue)
5. Last year and at beginning of this season, I realized that both turbos were stuck again and also showed signs of corrosion, soot and salt buildup
6. Last year and this year we cleaned them manually so that the turbines turn again at least

Why I believe the turbo is the source of the problem?

1. Yesterday I took a test ride with a local mechanic
2. He checked the line to the fuel pump and established low boost pressure
3. He then connected a compressor manually to the fuel pump to see if there would be a boost - and there was!
4. He concluded that the issue is somehwere between turbos and intercooler on the way to the fuel pump
5. Also worth noting: fuel pumps were serviced a few years ago and brand new K&N open air filters fitted this summer

Main conclusions & questions:

1. The mechanic suggested to remove the starboard turbo and to bring to a local specialist for testing and taking measurements. Fair enough.
2. But the main elephant in the room for me: how come the turbos potentially need servicing after such a short time of use? Fitted 2019, no usage until 2021 (Corona) which is when the issue appeared for the first time and persists until this day. And how come there's so much corrosion, soot and salt buildup? One wise commenter asked this above - wish I had checked in earlier
3. I read about the flawed elbow pipe of the VP TAMD 61A, which is build horizontally to the turbo and w/o any decline. Is that the source of my problem? Do I need to modify them in any way to protect the turbos going forward? Keen to get this sorted BEFORE I service the turbo(s), just to have the same issue next year again

Hope the above makes sense. Any input would be much appreciated!

Thanks in advance,

Mike

Check the bottom of the intercooler housing you may find is rotted away loosing your boost pressure.
Check the bypass valve flap isn’t stuck this causes the air not to flow through the intercooler .

 

[jms28]

Thanks for your replies. Just prepping for the 2025 season and will check all of the above and report back. Would you agree this is more sensible to be done first than removing turbo to be shipped to turbo expert? Not keen on doing that just to have problem persisting Thks!

 

[Seastoke]

Thanks for your replies. Just prepping for the 2025 season and will check all of the above and report back. Would you agree this is more sensible to be done first than removing turbo to be shipped to turbo expert? Not keen on doing that just to have problem persisting Thks!

Well if it takes you a year to talk about it ,good luck

 

[jms28]

Well I'm sorry, but unfortunately I only get to spent time on my boat around 2-4 weeks in the summers and don't live nearby. Furthermore, neither the marina has been able to help me finally sort this issue. So it is a bit of a needle in a haystack situation, against several other pressing priorities. If you have some wizardly advise to give @Seastoke, I'd be all ears ofc

PS: new crankcase filters will be fitted next week and I'm currently planning on installing turbo pressure gauges to get some better data (at least for the future, in case I don't get a reading on the dock). The marina failed to inspect and service the intercoolers in time for this season unfortunately, so alongside inspecting the fuel pump and intercoolers from the outside that's about all that can be done realistically for this summer... unless there are any other ideas?