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Volvo Diesel not starting.

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gshannon View Drop Down
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    Posted: 19 March 2018 at 19:08
The Volvo 2030 Diesel in my 2001 Hanse 371 suddenly refused to start. It turned over well and some smoke came from the exhaust, but no go.  One more bit of info, I used it for about 10 hours the previous week and had no troubles.

I called my mechanic down. He tested the glow plugs which were OK. Then he bled the system and got it running. It ran fine for him. 

The next morning I went down and tried it. Again it would not start. Obviously air leaking into the system. I opening up the tank area under the aft berth for inspection. The hose from the tank shutoff valve to the Racor fuel filter was very slightly damp near the valve. The mechanic replaced the hose, bled the system and again it ran fine. Next morning it failed to start. Again!

This time the hose and the hole fuel system is clean and dry. I think the air leak must be on the "suction" side as if it was on the pressure side of the fuel pump it would be leak fuel and show.

On the suction side there are the following components:
Pickup tube
Ball shut off valve
Hose from valve to Racor
Racor Fuel Filter
Hose from Racor to fuel pump

The question for others on the forum:
Have you experienced a similar problem? If so, any ideas which component is likely to be the culprit? 

Thanks!
Grahame

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samuel View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote samuel Quote  Post ReplyReply Direct Link To This Post Posted: 19 March 2018 at 20:04
On the 2020 there is a gauze filter in the lift pump. Have you got one in the 2030? if so have you checked it?
On my system I inserted a bulb pump (http://www.halfords.com/workshop-tools/tools/hand-tools/laser-diesel-fuel-pump-priming-tool). This is handy for bleeding the system plus when pumping it one can hear the fuel running through the line & back to the fuel tank so one knows that there is no blockage & fuel is running freely. Saves messing about with the lift pump & much quicker


Edited by samuel - 19 March 2018 at 20:10
Daydream Believer- Hanse 311- No GBR9917T- Bradwell Essex
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gshannon View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gshannon Quote  Post ReplyReply Direct Link To This Post Posted: 19 March 2018 at 22:53
Thanks. The bulb pump would certainly help bleeding the system. But my main concern is where is the air coming from. The engine has just over 2000 hours and has always started before. It even started without bleeding after I ran the fuel dry on my way to Alaska.
Grahame

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samuel View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote samuel Quote  Post ReplyReply Direct Link To This Post Posted: 20 March 2018 at 10:09
Thoroughly dry all the pipes with paper towels . Then lay dry absorbent paper towels under the pipes & leave then for a day & see if there are any wet patches. Failing that try sprinkling baby powder under  the pipework & around the filter seals

If there are any leaks you will quickly see it in the powder & it is easy to clean off afterwards. I find that with the bulb pump it pushes fuel out of any small leak & I can find it fairly quick as it pressurises the pipe a small amount
It is also useful for establishing the source of leaks around the boat .

I know that you have a different filter to mine (I have a CAV/Delphi) but I fitted extra long hoses each side of the first filter. Then I mounted the filter on studs set in the bulkhead. Now I can undo two nuts & ease the filter unit out of the engine bay just enough to hold it over a bucket whilst still connected to the fuel line. This means I can, 1) change it without a mess, 2) check I have reassembled it properly without any leaks & seals are seated correctly. Then I can slip it back on the studs & do the nuts up.
Solved a lot of leak problems
Daydream Believer- Hanse 311- No GBR9917T- Bradwell Essex
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gshannon View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gshannon Quote  Post ReplyReply Direct Link To This Post Posted: 20 March 2018 at 15:44
Thanks for this. The mechanic's plan is to bypass the filter and shutoff valve with clear hose to show any air bubbles. The hoses are completely dry and nothing shows on paper towels. It seems if the leak is on the suction side there might not be visible fuel. The bulb pump would allow pressurizing it.

The worst possible thing would be a crack in the pickup tube inside the tank. It is welded in to the stainless steel tank. 

I'll post the results of the transparent hose test here when I know.



Edited by gshannon - 20 March 2018 at 15:45
Grahame

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gshannon View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gshannon Quote  Post ReplyReply Direct Link To This Post Posted: 21 March 2018 at 00:24
The mechanic called me this afternoon. Apparently the engine has at least one bad injector. Injectors are in effect a one way, high pressure valve. If one sticks open, it can flood the engine making it hard to start. It can also allow air back into the injector pump when not running. The engine has over 2000 hours and as far as I know the injectors have never been touched. Anyway the injectors and pump have been removed and sent for rebuilding. In a week or so I hope to have a running engine again.
Grahame

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samuel View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote samuel Quote  Post ReplyReply Direct Link To This Post Posted: 21 March 2018 at 07:14
2000 hours is nothing on a diesel when one considers how long a car runs without injectors needing service
Daydream Believer- Hanse 311- No GBR9917T- Bradwell Essex
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Post Options Post Options   Thanks (0) Thanks(0)   Quote robh Quote  Post ReplyReply Direct Link To This Post Posted: 22 March 2018 at 15:06

Hi Grahame,

I agree with Samuel on the injectors. I have had a number of diesel engines on boats and cars with thousands of hours/miles logged. Every time a problem has occurred the pump has been found to be the culprit.

I wish you luck that this is the cure and look forward to the positive feedback that your problem has gone away soon.

Cheers,

Rob
"Blue Horizon" Hanse 341#113 Portsmouth Harbour UK
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gshannon Quote  Post ReplyReply Direct Link To This Post Posted: 22 March 2018 at 20:57
The mechanic took the injectors and the pump away for testing. No report as yet.
Grahame

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Sea-U View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Sea-U Quote  Post ReplyReply Direct Link To This Post Posted: 23 March 2018 at 09:27
When you talk about injectors...
On my previous boat with a Volvo 2002, I thought I had problems with the injectors.
On test they were spraying in all directions and looked terrible.
I bought two new ones (expensive), but .....
No change at all on the motor. Still hard to start and not full power.

I do not know what was the trouble... might be the pump!?

Sea-U is a 370e #532 located SW Norway
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