Fuel tank debris - warning

[Yacht Breeze]

I have become aware that there's been a problem with debris in the fuel tanks of new Bavaria boats. What appears to have happened is that when holes are drilled in the tank the 'swarf' and other plastic debris is not cleaned out. This leads to blocked fuel pipes and engine failure. It is hardly credible that it can happen but it has and it's not a 'one-off'.

I understand Bavaria blame their sub-contractor but ultimately it is their responsibility and reveals poor quality control.

If you've suffered blocked pies caused by plastic 'bits' then the only remedy is to have the fuel tank(s) emptied, the fuel filtered, the tank cleaned and the fuel returned to the tank. It'll cost around £300 ... a bill you might reasonably feel belongs to Bavaria and not the owner.

[Nigel]

The swarf often gets trapped in the fuel shut-off, which can be dismantled. Also, blow backwards along the pipe from the first filter, then suck any debris out of the bottom of the tank (easier when empty).

[Yacht Breeze]

Hi,

Thanks for that. That's exactly what we have found the fuel cut-off valve traps the 'swarf' but in so doing blocks fuel flow causing engine to fail.

From your description it suggests this is a 'known problem' rather than one-off. I've come across several people who have suffered same problem with their Bavarias - have you noticed others too?

Regards.
 

[KAOS]

In case of any debris i had installed an inline filter between the fuel tank and the stop cock. Worth considering it.

[TonyS]

I have also just had this problem with lumps of black diesel bug. I couldn't blow through the inlet pipe to the filter and had to use an electric cycle pump. I thought it was then solved. 2 hrs running later and it was blocked and again the same day. I then took the clips off and undid the compression nuts on the shut off valve. I blew through it and 3 lumps the size of a pea and lots of smaller bits came out. I then ran for 20 hrs without problem. However, a Volvo engineer told me it acts as the pre-filter and is too small with a very small orifice. I am now trying to get a ball valve with a big hole to replace it. Apparently Volvo advised their engineeers to drill a bigger hole in it. I couldn't find how to get it to bits and anyway ball valves are very cheap.
My advice is when you change the pre-filter element, to at least take the valve off and blow through it. Or replace it. It can be very dangerous to suddenly lose one's engine. We have done 1400 hours before this occurred.
Incidentally I have a pipe to the bottom of the tank and take a litre of discoloured fuel out every year. Even now there was only about a cup full to throw away.