Volvo Penta 2003 Leaky Heat Exchanger on Zephyr - What I had to do ?

Volvo Penta 2003 Heat Exchanger Cleaning. Dismantling the Heat Exchanger from a Volvo Penta 2003D marine engine. This one leaked and corroded quite badly. So I dismantled it completely, cleaned, re-painted it.
Learn with me how to remove and replace the Heat Exchanger, the complexities of the push on tube connections and the difficulties of working in a small space.
Volvo Penta 2003D Heat Exchanger refurbishment. How to dismantle the Heat Exchanger from a Volvo Penta 2003D marine diesel engine.
This is a 2003D the 2003T (turbo) is different.

[@maxsothcott4484]

Seriously glad I haven’t got a heat exchanger! Excellently presented as usual Dave! Hope you get out at Easter or soon thereafter and have the most superb and long season!

[@cokemachine5510]

I converted the engine coolant exchanger and the oil exchanger from a volvo 2003t to more standard exchangers , very easy, and now the exchangers can be mounted away from the engine. Worked well. A replacement oil heat exchanger from Volvo was $2500.00.

[@dreamtimesv]

An excellent video, very useful if you are a VP owner. I am not but you still lots of good learnings from your experiences. Thank you. Best

[@cdurant2756]

Have a great season Dave

[@AhoySkylark]

Bravo, this is exactly what I have been looking for! I have a VP 2002 also with the elbow and rubber hose at the raw water intake in place of the solid pipe from the raw water pump, and that's where it leaks. Fortunately for me I'm on fresh water so there's no corrosion to speak of. The yard wants to order new parts but it looks like all I need is a rebuild kit with the rubber parts and I can have a go at it.

[@ChrisDenny28]

I have the VP 2002 and went through this problem last summer. After a lot of effort to try to secure the press-fit copper piping to stop leaks, I gave up. Instead of using silicone grease, I used a little bit of RTV around each of the fittings. It remains flexible. It's water proof. No more leaks in my cooling system for $9! ....I know it's not how volvo wanted it, but it works great.

[@BOOMERANGSAILING]

Thanks for sharing. Working on the heat exchanger is one of my least favorite tasks. Well done.

[@jcfgh]

Thank you. Very instructive. Happy sailing

[@SverkerUllerstam]

I have a volvo 2003 t. It s evenmoe difficult than 2003 vith an oilcooler hidden behid the heat exchanger. It is made of aluminium copper and with saltwater in it has a tendency to coroode!

[@collinyoung7603]

Great video, I’m struggling with how the exchanger goes back together, watched the video close and am not seeing it? Do the 2 holes in the gasket line up with the 2 holes semi circles on heat exchanger? Pictures are at a premium on the internet. Any help appreciated!

[@mansourbenyamina2157]

Thank you for the explanation. I have a question. If you have time, there are four places for the hoses, two in front, one from the top and another from the bottom.

[@benlsbls]

I'm currently searching for broken impeller bits. The raw water copper pipe in has play in it when i out back together. It seems your pipe did too?

[@pauldent7067]

Unfortunately Penta's seem to have quite common problems on the heat exchanger and the exhaust elbow, every owner i've known have had some sort of issue with them, not good considering their over exhaubatant spares pricing.