Following calls from a client who reported his Marine Leisure Volvo Penta AQAD40 engine had begun to make a loud noise when running, our dedicated Volvo Penta 24/7 breakdown engineers attended and investigated the fault.
Once on site, the engineer investigated the fault and immediately requested that the engine was not ran any longer. The rocker cover was removed from the engine and a valve spring was found broken. The cylinder head was then removed in situ to determine if valve to piston collision had occurred.
Once removed the extent of the damage was found to be much worse than expected. Another cylinder was found to have dropped a valve seat causing damage to the piston and liner.
Due to the location of the engine in the vessel, the engine was removed and taken back to our custom built engine repair facility in Great Yarmouth.
The engine was then stripped further and the damaged piston and liner replaced. The main big end bearings were replaced during rebuild along with all required genuine Volvo Penta standard rebuild parts.
As the cylinder head was found to be cracked around the original seat location, a cold weld procedure was undertaken. Once complete our team of engine machinists carried out an oversize valve seat installation, along with a full set of valve guides. All valves and seats were machined and re installed to the cylinder head following pressure testing.
Once complete, the engine was installed on our dynamometer test bed for testing. Following successful testing, the engine was given a new coat of Volvo Penta green paint and returned to the customer for re installation to the vessel.