Sailing Zephyr IV · video

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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

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