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Diesel injection pump renovation and assembling engine parts (part two)

December 2018

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.

Some more paint on the engine block and new paint on the cylinder head while we still had it on the engine stand.

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.

Our diesel injecton pump before taking it apart.
All of the parts in the diesel injector 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.

The valve cover, diesel injection pump, water pump  and the holder for the heat exchanger mounted.
New paint on the exhaust manifold.
The impeller for the sea water pump.
The starter engine mounted onto the engine, and new gaskets for the connections to the exhaust manifold.
The cover for the flywheel mounted.
The engine before mounting the exhaust manifold.
Mounting the heavy exhaust manifold.
Exhaust manifold at its place and some new paint added on the engine.
Not much left to add on the engine now!

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.

 

 

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Disassembling internal parts of Volvo Penta engine

November 2018

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.

The pistons removed. They looked quite good at first sight and the piston rings were loose. We had suspected that they would be stuck since we had bad compression in the engine. We will probably buy new pistons anyway even though they looked good.
This is one of the liners. Some of them had really bad corrosion, so we will try to buy new ones.
Removal of the camshaft.
The flywheel removed.
The flywheel completely removed. A lot of grease and dirt inside…
The crankshaft is next to be removed.
The crankshaft removed.
Finally we removed the crankshaft bearings.

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:

Outsource:

  • 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

Buy new:

  • Pistons
  • Liners
  • Piston rings
  • Cam followers
  • Push rods
  • Crankshaft bearing
  • Connection rod bearings
  • Freshwater pump
  • Gaskets

Repair

  • 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.

 

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Teardown of Volvo Penta MD19 (outer parts)

November 2018

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.

starting teardown of volvo penta md19
We started with removing the heat exchanger.
The heat exchanger removed.
The connection between the heat exchanger and the exhaust manifold had corroded a lot. It also looked like it had been “repaired” earlier by using some kind of rubber.
Removal of the exhaust manifold. It is made of cast iron and is therefore very heavy.
Exhaust manifold removed! (The cute dog in the background belongs to Thomas parents)
Next thing was to remove the starter engine.
Starter engine removed.
The injectors removed.
The injectors.
The starter engine, seawater pump and oil cooler.
The diesel injection pump and seawater pump removed.
removing valve cover volvo penta md19
Removing the valve cover. In this picture the freshwater pump is also removed.
The valve cover removed. Inside here the valve mechanism can be seen.
Taking out the valve mechanism.
The inside of the valve cover with valve mechanism removed.
cylinder head removed volvo penta md19
The cylinder head removed. It didn’t look like there was something wrong with it, without removing the valves. We will outsource the service of the cylinder head, since we don’t have the right tools to do it ourselves.
Cylinder head removed.
Turning the engine around so that we can remove the oil sump.
The oil sump removed. The sump was very dirty and black.
Dirty oil sump.
The inner parts of the engine seen from below. Lots of dirty oil here.
Not much left of the engine now. We also started to remove the outer parts of the flywheel.
Removing outer parts of the flywheel.

There are a lot of small parts when doing a tear down of an engine. We put all screws and other small parts in plastic bags and put a note in each of them with the name of part of the engine they belonged to and in which order we took them off. This took some time to do when taking the engine apart, but when we started putting the engine back together it saved a lot of time.

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.

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Start Volvo Penta MD19 problems

August 2018

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.

diesel injection pump volvo penta md19
The diesel injection pump before we started to remove it.
start volvo penta MD19
The cover of the diesel injection pump removed.
start volvo penta MD19
Starting to remove the diesel injection pump.
diesel injection pump renovation
The diesel injection pump removed from the engine and ready for some service.
start volvo penta MD19
A picture of the cam ring. The brown dirt coating seen in the picture is what caused the pistons in the pump to get stuck. There where dirt coating all over the injection pump, which we cleaned. The dirt coating had emerged because the engine hadn’t been run in 10 years.
The pump unit for the diesel injection pump.

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.

start volvo penta md19
We were able to start our Volvo Penta MD19 and took a first drive!

We drove in circles outside Djurgården in Stockholm, and got a feeling for how she behaves in water.

Driving in circles outside Djurgården in Stockholm.

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.