Volvo Penta D2-40

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   Hi RogerThey checked the heat exchanger before they decided that it was the head gasket, apparently that was all ok. There was no obvious damage to the head gasket, but they seem to think head is warped, but will only find out tomorrow. 
On the MDI issue the last one literally lasted one engine cycle, turn on ok turn off ok, try to turn on again blown. Various different theories abound, back eddy from the stop solenoid, problems with temperature sensor. But Volvo don’t seem to take the matter seriously and have refused to replace the last two units. No proper reason given, but think due to the fact that until recently I always carried a spare on board and was therefore fitting them myself rather than have Volvo do it. 
All the best
Paul

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415 Singapore Members Profile Send Private Message Find Members Posts Add to Buddy List Vice Admiral Joined: 23 September 2013 Location: Singapore Status: Offline Points: 935	Post Options Post Reply Quote 415 Singapore Report Post Thanks(0) Quote Reply Posted: 06 August 2019 at 12:53
	Hi Roger They checked the heat exchanger before they decided that it was the head gasket, apparently that was all ok. There was no obvious damage to the head gasket, but they seem to think head is warped, but will only find out tomorrow. On the MDI issue the last one literally lasted one engine cycle, turn on ok turn off ok, try to turn on again blown. Various different theories abound, back eddy from the stop solenoid, problems with temperature sensor. But Volvo don’t seem to take the matter seriously and have refused to replace the last two units. No proper reason given, but think due to the fact that until recently I always carried a spare on board and was therefore fitting them myself rather than have Volvo do it. All the best Paul
	Paul - Night Train - 415 #136

Persephone Members Profile Send Private Message Find Members Posts Add to Buddy List Sub Lieutenant Joined: 17 July 2017 Location: New England, US Status: Offline Points: 17	Post Options Post Reply Quote Persephone Report Post Thanks(0) Quote Reply Posted: 06 August 2019 at 23:17
	I’m on MDI number four. Strangely, the part number that is supposed to be fitted under the replacement campaign is 23231607. However, my last two replacements under the campaign were part number 23195776 — in fact the most recent replacement came in a box marked on the outside as 23231607 even though the part inside was 23195776! Why do they fail? I certainly don’t know, but electronics generally dislike heat, vibration and voltage transients, so mounting it on the engine and taking its power from the starter (rather than from the battery) seems like a good recipe for failure. Good luck with the aftermath of your overheating problem.

Fendant Members Profile Send Private Message Find Members Posts Add to Buddy List Admiral Joined: 03 November 2012 Location: Switzerland Status: Offline Points: 1671	Post Options Post Reply Quote Fendant Report Post Thanks(0) Quote Reply Posted: 07 August 2019 at 05:17
	Paul, make sure that the workshop does a proper job renovating the head and block surfaces. If they use a cheapo manual milling machine or a chinese / american CNC machine I would insist to put both on a flat grinder after milling. You can get a good surface with high speed milling, but these are normally not found in an engine repair shop. Good Luck!
	Frank

415 Singapore Members Profile Send Private Message Find Members Posts Add to Buddy List Vice Admiral Joined: 23 September 2013 Location: Singapore Status: Offline Points: 935	Post Options Post Reply Quote 415 Singapore Report Post Thanks(0) Quote Reply Posted: 07 August 2019 at 11:38
	Hi Frank Thanks for the advice, our new Volvo agent / engineers assure me that they send these to a specialist engineering shop for machining, so hopefully they have all the right equipment. All the best Paul
	Paul - Night Train - 415 #136

415 Singapore Members Profile Send Private Message Find Members Posts Add to Buddy List Vice Admiral Joined: 23 September 2013 Location: Singapore Status: Offline Points: 935	Post Options Post Reply Quote 415 Singapore Report Post Thanks(0) Quote Reply Posted: 09 August 2019 at 15:11
	Hi latest update; The head was measured and can be milled / polished back to flat which is good news. We visited the workshop today and they had taken the heat exchanger and exhaust elbow off. Below is a photo of the exhaust end of the heat exchanger, which shows two holes between the exhaust and the coolant chambers. They reckon that this was the initial cause of our problems and suggested that if you do not run the engine at least every 2 weeks, the "stagnant" salt water can corrode the metal. I have checked the Volvo user manual and they do indeed suggest the engine should be run every two weeks and that if you intend to leave it more than two months then you should 'inhibit' it. We have never not run the engine for two months, the longest period might have been 4 weeks, but is usually every week. With regard to the litany of broken MDI units which certainly didn't help our situation, they say that the Volvo 2 year warranty only extends from the date of the original purchase. I bought two of these in October 2016 after a lightning strike took out the original, so despite Volvo giving me five further units since then, the latest being in June 2018, these are now out of their perceived warranty period. I am staggered that a company like Volvo can design an engine for a marine environment that is so sensitive and that despite accepting the problem with their MDI units (and recalling some) they fail to honour their obligations. Apologies for the rant, but seriously unhappy All the best Paul
	Paul - Night Train - 415 #136

High Time Members Profile Send Private Message Find Members Posts Add to Buddy List Vice Admiral Joined: 04 September 2012 Location: Portsmouth UK Status: Offline Points: 819	Post Options Post Reply Quote High Time Report Post Thanks(0) Quote Reply Posted: 09 August 2019 at 17:40
	Hi Paul This is truly shocking and I completely understand why you are seriously unhappy. Although I try to run my engine every 2 weeks or so, even through the English winter, it can occasionally be 3 or even 4 weeks between runs if we have been away, and there must be thousands of D2 engine owners who run their engines less often than you and I do. Are Volvo actually suggesting that there is a risk that ALL these 'neglected' engines could fail due to salt corrosion? If this is a real threat then Volvo should have designed in a more robust casting or possibly included anodes in the seawater circuit. I think you have a strong case against Volvo, for the above casting fault and also the appalling saga of the failing MDI units. It might well be worth trying to mobilise social media (if you subscribe - I don't) or publicise your story on the UK PBO Forum (http://www.ybw.com/forums/forumdisplay.php?13-Practical-Boat-Owner-s-Reader-to-Reader) and the US Cruiser Forum (http://www.cruisersforum.com/forums/f54/) and see what support you can muster for a campaign for better support from Volvo. Maybe just the threat of doing this will make Volvo take more interest. Good luck. Edited by High Time - 09 August 2019 at 17:41
	Roger High Time (415 #038)

High Time Members Profile Send Private Message Find Members Posts Add to Buddy List Vice Admiral Joined: 04 September 2012 Location: Portsmouth UK Status: Offline Points: 819	Post Options Post Reply Quote High Time Report Post Thanks(0) Quote Reply Posted: 10 August 2019 at 12:43
	Hi Paul Further to my previous and my comment in your new thread, I've just found this thread on the Cruisers Forum regarding the MDI issue. http://www.cruisersforum.com/forums/f54/volvo-penta-mdi-black-box-failures-188440-2.html
	Roger High Time (415 #038)

415 Singapore Members Profile Send Private Message Find Members Posts Add to Buddy List Vice Admiral Joined: 23 September 2013 Location: Singapore Status: Offline Points: 935	Post Options Post Reply Quote 415 Singapore Report Post Thanks(0) Quote Reply Posted: 10 August 2019 at 12:59
	Hi Roger, Many thanks for that, I will look into posting on the sites you suggested All the best Paul
	Paul - Night Train - 415 #136

Robin Members Profile Send Private Message Find Members Posts Add to Buddy List Sub Lieutenant Joined: 07 September 2023 Location: Salcombe Status: Offline Points: 4	Post Options Post Reply Quote Robin Report Post Thanks(0) Quote Reply Posted: 19 June 2025 at 05:29
	Came across a website which claims to explain repeated failures of the MDI box ‘If the battery is poorly connected, it can lead to high reverse voltages appearing at the MDI box supply. This has demonstrably killed many, many modules, sometimes several in succession, with the blame usually going towards the black box and Volvo Penta, when it is in fact an installation problem.’ https://nordkyndesign.com/engine-reliability-a-look-at-the-volvo-penta-mdi-black-box/ Another theory to add to the pile!

415 Singapore Members Profile Send Private Message Find Members Posts Add to Buddy List Vice Admiral Joined: 23 September 2013 Location: Singapore Status: Offline Points: 935	Post Options Post Reply Quote 415 Singapore Report Post Thanks(0) Quote Reply Posted: 19 June 2025 at 09:39
	Hi Robin, thanks for that in depth report. I agree it seems logical to take the MDI off the engine away from heat and vibrations. But at the end of the day Volvo designed it to be fixed to the engine and the unit is clearly not sufficiently robust to serve its purpose or deal with any non extreme fluctuations in voltage. The first 3 or 4 failures we had came when the boat was under two or three years and so the electrical system was as ex factory. My two cents worth! All the best Paul
	Paul - Night Train - 415 #136



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