Volvo Penta 2003 Engine Service on Zephyr IV. I did it myself ! 

Hi Louise, I'm so glad you found the video useful. The basic service is not that difficult, just a bit messy with diesel and oil. Take your time and good luck with it. Glad you're enjoying your boat and sailing. It's a wonderful hobby.. Take care .... Dave

You're very welcome Laurence. I'm sure you could do the basic filter change and oil change, it's a bit messy but it gets easier every year. Highly recommend keeping a log and include details about the filters, difficulties you experience and tools you used, spanner sizes etc. Good luck with your new boat hope it all goes well... Dave

Thank you for the praise, I just tried to show it as it was. Despite its age the Volvo Penta 2003 works well. I look after it like a baby, change the oil and all the bits every year and up to now it's looked after me.. Dave

Thank you so much Jarle, it went a bit better this year but filming it did make it more difficult, especially when my hands get a bit oily (despite the paper towel :-) and I worry about damaging the camera. The bit that didn't come out too well was bleeding the CAV filter. Despite my best efforts it started leaking diesel and I had to strip it all down and start again - and needed lots and lots and lots of paper towel :-) and I forgot that I hadn't filmed the air bleeding bit. So I fudged, when I edited it. Oh you've done the falling over bit too :-). Last year I had to move quickly and moved my foot away quickly but it was on a newspaper that a bottle of waste oil was standing on. My foot pulled the newspaper away, litre of waste oil all over the floor. One of those occasions when you need another pair of hands. It must be nice to service an engine on one of those nice stands that you see in showrooms. I'm pleased with how quickly the engine starts though. I saw a video the other day where the engine turned over 10 or more times before it fired. Zephyr IV's turns over once and it's away. Hope you have a lovely Christmas, Take Care .. Dave

Thanks Stuart, who's got a nice shiny boat now? :-) She looks lovely. Ok on the alternative parts. I thought I'd try to go with proper Volvo parts and then I could relax. But this year I realised that Volvo themselves used alternative suppliers, so next year I'll probably look elsewhere. I'd seen the Parts4engines web site but just felt safer going with the Volvo bits. I'm no engine expert :-) But maybe next year. I'm always surprised the engine starts after I've finished the service :-) See you in the New Year, Have a lovely Christmas... Dave

I did the same, the CAV filters are terrible things to reassemble esp in an emergency. Racor all the way.

Hey glad you found it interesting. It was tricky to film, sometimes holding the camera in one hand and working with the other. I need a camera man :-)

Thank you Gustavo, glad it was of some use.. Dave

Thanks for the tip 🙂

Well I initially didn't think there was and then I found a couple of unused anodes in the spares kit that came with the boat and found videos showing how to change it. BUT I can't find one where I expected it to be. So now I'm just as uncertain as you. Sorry 😞... Dave

Hi Chris, I think it's the engine temperature sensor. The thermostat is up there. You'll find the Vovo Penta service manual online. That should tell you for sure.

@@davesailing Thanks! I also thought it was a temp sensor, but I was surprised to see it in that location. I have a sensor that I can't identify on my 2002. It is behind the alternator and right below the thermostat. It has 2 prongs sticking off of it. I can't seem to identify it via the owner's manual or shop manual. Do you have a sensor there too?

@@ChrisDenny28 Hi Chris, I'm not sure. I'm away from the boat at the moment but will be back on board at the end of next week. I'll have a look then and get back to you... Dave

Hi Ronald, I'm not a diesel engineer but there are lots of youtube videos about the problem. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-iveMg6UhDFo.html is a good start. If I had the problem I wouldn't tackle it but would get a qualified engineer to do the job. It usually means getting the head off so I guess I would describe it as a fairly big job. I have a good engineer contact and I asked him what problems he'd experienced with Volvo Penta engines and he immediately said, "Owners interfering with the injectors and damaging the cylinder head." I hope you can sort it out soon. ... Dave

I didn't forget them, I showed the one on the drain plug at the bottom but somehow didn't include the bit of video showing the top one.. :-( Thanks for the comment, I hope you subscribed, do take care :-)

@@davesailing cheers mate there is 6 to change on them - drain bung - bolt oring under top washer - the 2 between the glass and the top large one - 1 beneath the top of the filter to separate the clean and dirty fuel Just giving you the heads up mate Just subscribed 👍

Thanks gor that and subscribjng😊😊

Hi George, I'm not a diesel engineer but you'll find a lot of information by asking Google, "What makes Volvo Penta Diesel Engines Smoke". A lot depends on what colour the smoke is. Black usually indicates too much fuel, blocked intake filter, there's a whole list of things. Blue is the worrying one, that's usually due to engine wear and oil getting past the piston rings and burning. If it was me I would try a diesel fuel additive, which would help clean the fuel pump and injectors and valves. Maybe it would pay to talk to your local engine man 🙂 Good luck with it, let me know how you get on.

Hi James, to be honest, I'm not sure. However I do know that the anode on the Hull is connected to the engine, so presumably that would provide the protection.

no anode@@davesailing

You're welcome, thanks for watching.. Best wishes... Dave