Sailing Zephyr IV · video

What this video covers

Refurbishing a leaking heat exchanger on a 30-year-old Volvo Penta engine requires removing the unit from a confined space, stripping corrosion, and resealing the end caps.0:03 To remove the exchanger, close the raw water seacock, drain the freshwater coolant, and disconnect the four coolant and seawater pipes.0:50 After removing the mounting bolts, clean the barrel and end caps with wire brushes and paint remover, then use chemical metal filler to repair dents on mating surfaces.5:08 Flatten the end surfaces on a flat glass plate with abrasive paper to ensure a proper seal.5:26 Reassemble the unit with new gaskets and O-rings, using silicone grease on all mating surfaces to prevent leaks.7:08 Secure the seawater pipe connections with the manufacturer-specified retaining plate to prevent them from vibrating loose.17:26 If leaks persist after reassembly, the barrel may be deformed, requiring a replacement unit.18:29 Using silicone grease on gaskets and mating surfaces is essential for achieving a watertight seal on older, potentially uneven heat exchanger components.13:16

Boats in this video

More from Sailing Zephyr IV

Why Cowes Can Be A Sailor’s Nightmare (And How To Fix It)Sept 2026I Took the BLUETTI Elite 100 V2 on a boat – Here's What HappenedAug 2026Day in the Life of a Solo Sailor at 82 : Cowes to PooleJul 2026Boat Toilet Not Working? I Replaced the Jabsco Pump at 82!Jul 2026

From Sailing Zephyr IV — see the channel’s boat, crew, and every analysed video.

The Sailing Directory Newsletter

One email with the fleet's best finds — the moments, boats, and stories worth your watch time. Enter your own address to get your own copy.