Cost for Volvo Penta renovation

It is about time to share the cost for our Volvo Penta MD 19 renovation. As said earlier we have done most of the work ourselves and spent some time finding cheap spare parts on the internet. If you want to know more about where we found all the spare parts, click HERE.

cost volvo penta renovation
The smaller costs related to our Volvo Penta renovation. More information about the costs can be found below.
Pistons/Piston Rings/liners

Ordered from internet to what we think was a reasonable price. The main issue here was that it was hard to find the correct liners.

Cylinder head

We outsourced the service of the cylinder head since we didn’t have the correct tools and this is the price we had to pay for that job.

Engine parts

This post is much of the spare parts we bought, and it includes:

  • Gaskets
  • Crankshaft bearings
  • Cam followers
  • Push rods
  • Engine mounts
  • Connection rod bearings
  • Freeze plugs
  • … and other small spare parts
HEat exchanger

We had to fix the connection between the heat exchanger and the exhaust manifold due to bad corrosion. We outsourced that part to the same guy that fixed the cylinder head and this is the price we paid for that service.

Water pump

The service kit we bought for the circulation pump.

Other Engine Renovation cost

This a description of the post for the other renovation costs in the table above.

cost volvo penta renovation
The smaller costs related to our Volvo Penta renovation. More information about the costs can be found below.
Crankcase ventilation

We made a new crankcase ventilation and this cost is some pipe fittings for that.

Thermostat

We bought a new thermostat since the old one had the wrong opening temperature.

Gearbox

The gearbox looked good and we only did minor changes to it. This cost is for new o-rings, sealings and gaskets for the gearbox.

Injectors

We left the injectors at a engine shop to do a pressure test of them. They looked pretty okay, and they just adjusted the opening pressure on one of the injectors.

Other small costs

This is a big post and includes all small parts that doesn’t cost that much but together they are a lot. The costs here includes:

  • New paint
  • Painting brushes
  • O-rings
  • Anods
  • Epoxykit
  • Cleaning articles
  • Dial indicator
  • Valve spring
  • Different kinds of gaskets
  • Fuel hoses
  • Etc

All blog posts related to our Volvo Penta renovation can be found under the category Engine. We have also added some new pages, where we will collect all our information posts so that they can be easily found. These pages will be updated as our renovation progresses. They can be found under Cost & Information.

Gearbox renovation and crankcase ventilation solution

In this blog post we will show our gearbox renovation and crankcase ventilation solution. For the crankcase ventilation solution we finally decided that we will pass the blow-by gases to the intake via the valve cover.

Gearbox renovation

We have a Volvo Penta RB gearbox, which we wanted to take apart to see that everything looked good, and change/repair what was necessary.

Starting to take the gearbox apart.
The interior of the gearbox.

We measured the wear on the gearbox. Everything was according to specification, so we will only change sealings and gaskets. One thing we noticed when taking it apart was that the old oil in the gearbox smelled like transmission oil, which is common to use for gearboxes, but for Volvo Penta RB gearbox you actually should use standard engine oil.

The new sealings, o-rings and copper washers for our gearbox. Volvo Penta spare parts are expensive so we bought all of these spare parts separately, which was much cheaper than it would have been to buy them as a complete kit. If you want to know where we found all our spare parts, click HERE.

Time for painting the gearbox!
Before painting…
… and after painting! 🙂

CrankCase ventilation solution

As said above, the solution we decided to settle with was to pass the blow-by gases to the intake via the valve cover. The reason we choose this solution is because we don’t want the blow by gases inside the boat.

A hole made on the valve cover.
The new fitting.
After welding on the valve cover. We (Thomas) aren’t very satisfied with this welding but it will do its job.
The fittings on the valve cover and the intake.
Finally adding some final paint on the valve cover and intake.

The next step of our Volvo Penta MD19 renovation will be to do the final painting and test-run it again to make sure that the leakages fixes we did works. If you want to read more about our engine renovation, all posts related to that can be found under the category Engine.

Assembling Volvo Penta MD19 (Part One)

December 2018

After we had cleaned all the parts of our engine and all the new spare parts had arrived it was time to start assembling our Volvo Penta MD19 engine. During the whole process of assembling the engine we used our handbook for Volvo Penta MD19 a lot. In the handbook all necessary torquing and measurements were specified.

The new pistons and liners.
Measurement of the height of the liners. The measurements were done according to our Volvo Penta MD19 handbook. The top of the liners relative to the engine block should be 10 um without the sealing assembled.
The new crankshaft bearings assembled.
The new pistons inserted. When we added them we added a lot of oil and made sure that we got oil on all the piston rings.
First piston added.
All pistons added. They were pretty hard to get into the liners. We used a compression tool as help, the tool compresses the piston rings together so that the piston would get inside the liner.
Crankshaft mounted..
Carefully adding grease onto the cams of the camshaft. This was done to make sure we will have a smooth run-in of the new cam followers.
The camshaft re-mounted into the engine block.
The final transmission gear and a new gasket.
The cover for the transmissions added onto the engine.
The oil pump.
The oil sump added onto the engine block.
The gasket between cyleinder head and engine block mounted.
The engine turned around and the gasket between the engine block and cylinder head.
This is how the cylinder head looked before. As mentioned earlier we had outsourced the service of the cylinder head to another guy since we didn’t have the correct tools.
And this is how the cylinder head looked like when we got it back! 🙂
The cylinder head mounted on the engine block.
Using a torque wrench to attach the cylinder head. We attached it according to our handbook, which meant attaching them in a certain order and tighten them a little bit in turn.
The valve mechanism added.
The engine is getting bigger again.

Next up will be to do some more service of the diesel injector pump and continue assembling the remaining engine parts. All of our blog posts about our engine restoration can be found under the category Engine, if you want to read more about it.

Finding spare parts for Volvo Penta MD19

November 2018

In this blog post we will share where we found the spare parts for our Volvo Penta MD19 (which is very similar to Volvo Penta MD21). Some of the spare parts were really hard to find, so hopefully this will help someone.

Most of the spare parts

We ordered most of our parts from Der Franzose. The Volvo Penta MD19 is based on an Indenor XDP-4.88 engine, which was used in some Peugeot cars, with external Volvo Penta parts to adapt it to a marine engine. From Der Franzose we ordered:

  • Gaskets
  • Crankshaft bearings
  • Cam followers
  • Push rods
  • Engine mounts
  • Connection rod bearings
  • Freeze plugs
  • … and other small spare parts
Liners & Pistons

It was very hard to find new liners for our engine. After searching through the whole internet (at least that’s what it felt like) we found them on Citroworld. It was a complete kit with:

  • Liners
  • Pistons
  • Piston rings
Non-original Volvo Penta Parts

At the website CromMarine we found non-original Volvo Penta parts. From CromMarine we bought:

  • new gaskets for the heat exchanger
  • a new thermostat
Gear box sealings

Sealing for our gear box we bought seperately at the swedish store, Kullager.se. They had the right measurements and this was a cheaper way to buy them.

Service Kit Circulation Pump

We ordered a service kit for the circulation pump from Indenor-retro. The service kit included:

  • shaft
  • bearings
  • pump wheel
  • shaft sealing.
sealings gearbox volvo penta md19
Sealings for the gear box.
spare parts volvo penta md19
Our spare parts for the engine which we ordered from Der Franzose.
mounting the freeze plugs onto the engine block
We mounted the freeze plugs onto the engine block, ordered from Der Franzose
pistons volvo penta md19 spare parts
The new pistons, which we ordered from Citroworld.
service kit circulation pump volvo penta md19
The pump wheel from the service kit for the circulation pump, which we ordered from Indenor-Retro.

Now when we found all our spare parts for our Volvo Penta MD19, the next step will be to put the engine back together with the new spare parts. If you want to read more about our service of a Volvo Penta MD19 engine, more blog posts can be found under the category Engine.

If you want to know more about the costs for our engine renovation, check out our blog post about, link to the blog post: Cost For Volvo Penta Renovation. All other costs for our sailboat renovation can be found under Cost & Information/Sailboat Renovation.