2008 IPS 600 port engine had salt water forming in the valley of the on top of the cylinder head. Discovered fuel in the coolant on routine inspection. Over time this resulted in corrosion of the copper tubing feeding the injectors and fuel to enter the coolant. The repairs are very expensive and now we find the same, to a lesser degree on the starboard engine. Out of Volvo warranty but still in Formula Guard. Found one other reference in the forum. Any suggestions as to cause?

Volvo Forums - Volvo Enthusiasts Forum > Volvo Vehicles > Penta
Volvo Penta D4 and D6 injector problems

09-07-2010 03:06 PM
by Wayne Kehler
I am in the middle of trying to resolve this very issue with my boat. The engines are installed in a 400SS Formula and it first manifested itself with diesel fuel appearing in the cooling system which intern started eating up and rubber in the closed cooling system. The rubber material was completely gone from the thermostat. Disassembly and a test showed a failure of one of the copper injector tubes. A new head was installed by a certified Vovlo Marine facility. I put an addition 2 hours on the boat after the head replacement and the engine experience a catastrophic failure. By this I mean, a large bang, clouds of blue smoke out the exhaust, loss of oil pressure and a severe knocking. At this point I don't know the extent of the failure. I would say the " only in Norway " theory is disproved. The boat is a 2007 and the engines have about 350 hours on them.

WK