2002 Bavaria 38 - Volvo Penta D2-55A - replacing heat exchanger

[Seagoon]

I have a 2002 Bavaria 38, which has a Volvo D2-55A engine installed. Recently we detected major corrosion in the heat exchanger where it joined up to the mixer elbow. We have patched the gap for now with Devcon metal-epoxy paste, but expect it won't last forever.

We have picked up a replacement heat exchanger (that hurt the credit card!) from our Volvo dealer but we can see the new part (3808561) differs from the original (number 3583086), which has now been discontinued. Links to the different parts diagrams are below. Volvo have suggested a service kit (3586996) is what it required but this seems to relate to installation of an expansion tank for the freshwater system (which I already have). Instruction for that are at https://drive.google.com/file/d/0Bx5MofyNFDO5d0VEZTRHaE5STXM/view?usp=sharing

Question - has anyone had experience with replacing the old with the new, and dealt with rearranging sea-water and freshwater pies, pressure sensors etc as seems to be required from the parts diagrams? Both we and the dealer are trying to figure this out (I am several hours flight from the dealer which makes it all the harder). A link to the correct conversion kit or guide would be good if there is one.

Best
Seagoon


Original part diagram is at https://www.marinepartseurope.com/en/volvo-penta-explodedview-7744440-26-5493.aspx
New part diagram is at https://www.marinepartseurope.com/en/volvo-penta-explodedview-7744440-26-21497.aspx
The "exploded" parts diagram for the old unit is here - https://www.marinepartseurope.com/en/volvo-penta-explodedview-7744440-26-7491.aspx
And for the new unit, here: https://www.marinepartseurope.com/en/volvo-penta-explodedview-7744440-26-9867.aspx
Old unit hot water connection diagram is at https://www.marinepartseurope.com/en/volvo-penta-explodedview-7744440-26-9958.aspx
New unit hot water connection diagram is at https://www.marinepartseurope.com/en/volvo-penta-explodedview-7744440-26-9959.aspx

Image of corrosion on old exchanger is at https://goo.gl/photos/fUEPzo7KpRVRPKn89

[Seagoon]

An update

I ended up replacing the whole manifold and heat-exchange unit, photos here https://goo.gl/photos/vjJjtD9KeEpjqoqs9

Volvo have't really documented the changeover from the old to the new style of manifold unit, but in the end it was straightforward enough. One hose for the hot water system needed to be shortened and brought around the back near the exhaust mixer elbow, and a new shaped Volvo hose now runs from the seawater impeller housing to the back of the unit. Temperature senders and plugs from the old unit fitted the new well enough, and the starter electrics had enough cable to move to the new mount point which is forward of the old.

6 1/2 hours work and AUD$4000 later. I imagine it will be a problem again in another 12 years.

[BenDB]

Hi Seagoon,

Long shot, but I hope you are able to help me.
We also have a hole in our D2-55A heat exchanger and everyone says it's best to exchange the heat exchanger and elbow. I had already ordered a new elbow, and now just ordered the new heat exchanger. The thing is: the old heat exchanger (part nr. 3583086) has now been replaced by part nr. 22898286.  ( i hope my new d2-55A elbow will fit this new exchanger?!)
Volvo says, however, in order to install this new exhanger. (cost 3600 eur!!) You ALSO need:

Part 3589546 (some hose?) - 121 euro
Part 3589547 (another hose?!) - 150 euro
Part 3586996 (a "kit" - nobody can describe me what this is ?!!?) - 485 euro (!).

2 Volvo dealers say i need the additional parts, 1 other Volvo dealer says I don't . . . . . .

Can you please let me know which of the above parts you had to order additionally in order to install the new model of heat exchanger??

Thanks a million

Brgds,
Ben

[PEA-JAY]

If you only have corrosion in the flange that meets the mixing elbow a good machine shop can save the heat exchanger by removing the corroded material, weld/rebuild it and re-finish the flange at a fraction of the prices mentioned on this thread. Regarding hoses I have successfully substituted hoses by re-routing, in fact rather than wait till the rubber hose, pump to heat exchanger failed, I changed it with wire reinforced toilet flush type hose. If I’m not mistaken I had also seen at the time a replacement heat exchanger made by Bowman and it wasn’t for the cost of a small car! Don’t forget the D2-55 is made by a Japanese or Chinese factory for Perkins who sell it to Volvo so options are available!

[symphony2]

Don’t forget the D2-55 is made by a Japanese or Chinese factory for Perkins who sell it to Volvo so options are available!

While it is true that the base engine is made by Parkins, some in Japan but others in Peterborough, the marinising including the heat exchanger is unique to Volvo, so no direct alternative available.