We had decided to do a diesel injection pump renovation once more to make sure that it was working smoothly. After that it was time to continue assembling the engine parts, see part one of assembling the engine HERE.
During the whole process of assembling the engine we painted it in stages. Since we have taken the whole engine apart we also wanted to make it look nice, and by painting it in stages we could get new paint everywhere. Of course, this is not only to make the engine look nice, but also to protect it.
Diesel injection pump renovation
We have done a small diesel injection pump renovation before (if you want to read more about it, click HERE) to make the engine start. Since we we were doing a complete service of our engine, we wanted to do the same to our diesel injection pump.
During our diesel injector pump renovation we did:
a thorough cleaning of all the internal parts
changed all sealings and gaskets
The old dirt coating on the mechanical governor made it lag, and that was probably the reason we couldn’t run very good on idling.
Assembling the engine
When we were satisfied with the diesel injection pump renovation we continued with assembling the engine parts. The engine were now starting to get heavy and we removed it from the engine stand.
Now we have everything we need to have connected to be able to do a first start. Then we will do some service to the circulation pump and the heat exchanger and final paintings. To see all our previous blog posts about the engine renovation, see category Engine.
When we had removed the outer parts we started disassembling the internal parts of our Volvo Penta MD19 engine. If you want to read more about our removal of the outer parts, click HERE.
During the process of disassembling the engine, we made sure that there wouldn’t be any dirt on the internal parts. For the internal parts we organized them so that we knew which part had been at a certain place in the engine and also which parts belonged together. We did this so that the parts we were to reuse would be re-mounted in the same location as they were before. The parts could been differently worn out depending on their location in the engine.
Now we have taken apart all the parts of the engine. All of the parts are really dirty and will need some proper cleaning. We will also have to decide which parts of the engine that we will outsource to someone else, repair ourselves, buy new or which parts that doesn’t need repairs or to be changed.
From what we know at this point we will:
The cylinder head. Since we don’t have proper tools for that service we will leave it to another guy.
The same guy will also fix the connection between the heat exchanger and the exhaust manifold
Connection rod bearings
The rest of the heat exchanger
The water pump
Diesel injection pump
The other parts not mentioned here seems to be in good shape, for example the camshaft, exhaust manifold etc. We will clean them and re-mount when it is time to do that.
The next step of our engine service is to clean the parts of the engine. If you are interested in reading more about our service of our Volvo Penta MD19 engine, then read more about it under the category Engine.
We were now ready to start the teardown of our Volvo Penta MD19 Engine (which is very similar to MD21).Our best friend during the teardown (and when assembling the engine) was the workshop manual for Volvo Penta MD19 engine.
The next step will be to disassemble the inner parts of the engine, you can read more about it HERE. If you want to read more about our service of the engine, you can read more about it under the category Engine.
Shortly after buying the boat we decided to start the engine, which is a Volvo Penta MD19. It had not been started in approximately 10 years, so we suspected we would have some problems. We bought a new start battery and went out to the boat one evening after work, but without luck. The good news was that the pistons were able to move and were not completely stuck.
We could not get any diesel to the injectors and suspected that the diesel injection pump was the issue so we removed it and took it home for cleaning.
We spent some days cleaning the injection pump. We put back the injection pump on the engine and tried to start our Volvo Penta MD19 engine, and it started! It was not without problems, though. We spent a lot of time bleeding the system before the diesel reached the injectors. There was also a lot of smoke coming out from the exhaust and the engine wouldn’t run on idling.
Since the engine hadn’t been running for so long, we decided to take it out for a tour the following day. We hoped that the engine needed to be running for a while under load to clean old dirt in the engine.
We drove in circles outside Djurgården in Stockholm, and got a feeling for how she behaves in water.
The tour didn’t solve the problems entirely. The engine still wouldn’t run idling and it was a lot of smoke. We also noticed that he engine died when changing to reverse. The next step we did was to remove the injectors and have them checked out. They had the correct opening pressure and a good spray pattern and probably works as they should.
Since the autumn arrived in Sweden we paused working on the engine for a while, so that we could fix the plastic cracks in the cockpit before it became too cold. We will continue working with the engine later on.
All about our further engine renovation can be found under the category: Engine.