I think I'm in real trouble

[Martin610]

Hi Guys,

So a few weeks ago my starter failed on my Cutwater with the D4-260. Got a mechanic to help and we discovered a leak in the heat exchanger. I told him to take it back to the shop, Monmouth Marine Engines here in NJ, to be fixed. We just needed to replace the oil cooler section. Not a huge deal.

They were supposed to come today but at the last minute they called me to cancel. Seemed weird so I drove by the shop. It was swarming with police! I was told the business was closed. I don't know for how long.

Now I find out the owners are under arrest. They are charged with defrauding the US Gov't. Wow!

This is beyond my experience. I'm worried about getting the HE back. I'll fix it myself, but I need the parts. Anyone have anything like this before? I don't know if I should talk to the police, get a lawyer or what. Any advice appreciated.

Here's the story from one of the local news organizations:

https://www.insidernj.com/press-release ... t-defense/

-martin

 

[Cutwater28GG]

oh gosh. sorry for the pain this will be. i just cant imagine this will be resolved quickly. it seems worth trying to contact the police to see if customers can get access to their items in the shop.

but it might just be easier and faster (not to miss out on the summer) to get a new HE ordered?

 

[Martin610]

We're going to the police tomorrow morning, find out what we can.

I took a look on the volvo penta store website. If I read it right, a new HE is $8500. Yikes! Hate to spend that if I don't have to.

-martin

 

[knotflying]

Legally the HE is yours. On the practical side it may be hard to get it. Just because they were arrested does not mean that they are not going to open for business. They should be out on bond and should be able to resume business, if anyone wants to continue having work done by them.
With that said, I am curious as to how a starter not working leads to a bad heat exchanger? Was it leaking onto the starter? That in itself seems odd.
I guess you have a financial choice if it will take a while to get your HE. Do you want to wait and lose precious boating time or bite the bullet and get a new one.

 

[Martin610]

Hi,

Well the good news is Monmouth Marine is open for business now. In fact I was there this morning, spoke to my mechanic and he had my HE in the van. All fixed and put back together, he says. He is going to install it this afternoon. Whew!

I read the US Attorney's criminal complaint online. As I read it the employees of the shop had nothing to do with the scam. Employees as in worker bees. Seems like the complaint is only against the owners.

How I got here is interesting too. One day I go down to the boat with the wife and it doesn't start. Odd as it always started well. Checked batteries, checked wires. Checked voltage. All good. Rapped starter with a hammer. Nothing.

At that point called Monmouth for a mechanic. They determined the starter was bad. They tried to get it out with a ratchet and knuckle but couldn't do it. The service procedure calls for removing the charge air cooler and HE. The starter is buried down deep.

A more senior mechanic comes out, takes off the charge air and HE. Gets the starter off, its a corroded mess. He sees what he thought might be a leak between the oil cooler (lubricating oil) module and the coolant heat exchanger. Must have dripped down on the starter over time. This is a good thing to check.I agreed to have the HE pressure tested and a leak was confirmed. I was at the shop when this was done.

I'm thinking the PO didn't change the zincs as often as needed. I'm religious about it. The zinc in there now was about half gone. I think its OK for this time in the season.

So we ordered a new oil cooler module, it comes in, and then nothing. Crickets. I'm like WTH?

Turns out the senior mechanic stopped coming to work. I held out for a few days but then agreed to have the 'kid' work on the boat. I'm sitting there waiting yesterday and then SHTF. They call me to cancel with a weird story. I drive by the shop and it's crawling with cops. Mostly detectives with gold shields. Weird. And I was pretty sure I saw an FBI T shirt.

By the time I get home the story had broken.

Pretty miserable night worrying about this. New HE is pretty expensive.

I drive to the shop this morning, and the senior mechanic is in the lot. This is the guy who really knows what he's doing. He's got my HE all put together as I said.

I think he got a tip and stayed away. I probably would too if it was me.

This was about as weird as weird gets for me. Hope to go for a boat ride tonight.

Bottom line, check those zincs. Use your cell phone and take a picture of that starter and address any leaks before it becomes a big problem.

-martin

 

[trailertrawlerkismet]

Glad things worked out positively Martin and thanks for the info n story. Enjoy your boat outing today.

Jim

 

[NautiTug]

I’m glad it seems to be working out! And people wonder why we here in Jersey get a bad Rap! Ha

 

[CaspersCruiser]

Martin, man, I am glad things got straightened out. Talk about opening a can worms! A simple starter replacement literally turned into a Federal case.

Good info otherwise.

 

[Cutwater28GG]

like a hollywood movie 🙂 great news on the resolution!

 

[Martin610]

Appreciate all the support guys. It really helps.

Thanks,

-martin

 

[BB marine]

A more senior mechanic comes out, takes off the charge air and HE. Gets the starter off, its a corroded mess. He sees what he thought might be a leak between the oil cooler (lubricating oil) module and the coolant heat exchanger. Must have dripped down on the starter over time. This is a good thing to check.I agreed to have the HE pressure tested and a leak was confirmed. I was at the shop when this was done.

This issue is noted by several Volvo technicians I have talked to. It is more of an issue in salt water use. Volvo has a service bulletin that involves flushing the engine and cleaning it with Oxalic Acid and a Nuetralising chemical. If the o-ring seals have started to leak the cleaning flushing is to late. The best fix is to remove the Heat exchanger and after cooler for cleaning. If the mating surfaces between the HE and oil cooler are ok replacement of the o-rings should resolve the leak. There have been several heat exchanger changer part number changes in the past years. The new part number used on current D4 models is used on the older models. (there is no information that States this resolved the leaking issue) Martins issue and posting of this issue should be noted by all D4 and D6 owners to include oil cooler to heat exchanger mating surface and end cover plate inspection as a preventative inspection. Finding a small about of corrosion around the split line is the first sign. The cost of a starter and the removal of all components is costly and inconvenient especially if you are a seasonal boater. It would be a large cost savings to catch this before it damages a starter.

As far as Martins issue, Martin I'm glad the issue you encountered with the service center worked out and you will be back on the water.

 

[vertigo]

"I think I'm in real trouble."

I humbly suggest that you merely had aggravation and expense.

The owners of that boatyard, they have REAL TROUBLE.

 

[Martin610]

Thanks Brian, this is very helpful.

This was an absolute bear of a repair, so you want to avoid this.

It's very hard to see any of this from top side. I have to use a mirror for inspection, or my cell phone.

I was lucky to have an experienced mechanic. Once we got the HE off, it was very subtle. Even he wasn't sure. I was hesitant as I wanted the boat back in action, but in the end I asked to take it to the shop for a pressure test. Sure enough, it leaked. But the corrosion was very small. I would have missed it, I think many younger mechanics would have missed it.

I have been using Barnacle Buster, which is phosphoric acid. I have no experience with Oxalic acid, I will have to look into that.

Are these service bulletins available to the general public?

-martin

 

[BB marine]

Are these service bulletins available to the general public?

-martin

Not to my knowledge. Volvo seems tight lipped on any issues with their product. Even ECM updates have limited publication. The best way to get the service knowledge seems to be through a Volvo certified service center. A service center that I worked at is a Volvo dealer. There are a few technicians that I worked with that are still there so I pick their brains and get information from them.

I have been using Barnacle Buster, which is phosphoric acid. I have no experience with Oxalic acid, I will have to look into that.

I think that if you are flushing your engine with fresh water periodically and use Barnacle Buster you are doing preventative maintenance similar to Volvo's service bulletin.

To add a thought to the inspection. Leakage would be most susceptible after a engine run when the engine temperatures are at operating temperature. This is when the metals are expanded from heat and may seep if there is a leak path.

When I replaced the Turbo on my D3 the service center recommended pressure checking the after cooler because of a possible seal failure. It appears that the end covers are bronze and the housing is aluminum. This split line is where the issues are. The seals are o-rings and as corrosion starts at the split line it could cause a leak path. This is common in many engine manufactures design.

 

[doke01]

It's a shame, then again they should be ashamed of what they were doing. Monmouth Marine was a great local supplier of Yanmar parts.