2002 volvo 3.0GS water ingestion #4 cyl

hey guys,
ive been working on a volvo 4 cyl 2002 3.0GS
it had a severe overheat
-pulled head, reconditioned and resurfaced
-new impeller, all gaskets, & riser replaced & restricter plate installed
-pressure tested exhaust mfld, and heated, had surfaced machined flat
- new exhaust flapper & thermostat
- new plugs, cap, rotor, wires Timming base @ 0 degres
any time i run this it idles with a slight miss #4
and if i race it and decel quickly it swallows water #4 every time?
this is being tested in the hose with flush ears on drive.
i have run out of things to try?
any ideas? apreciate any one who may have run into this before?
Rob

Re: 2002 volvo 3.0GS water ingestion #4 cyl

First off, you should be at 2? ATDC, not TDC. And, did you set the timing like this.
http://forums.iboats.com/showthread.php?t=271407

2 more questions. Does it diesel when you shut it off, and what is your idle rpm?

Re: 2002 volvo 3.0GS water ingestion #4 cyl

You know i seen this same problem before here. The manifold have a slight crack and you can't pressure test for it, opens up when it gets hot. And water is constantly going into #4 and it has to miss. Plug is always wet i bet.

You said new riser so not that.

The old flapper break loose and blocked the exhaust thats why you replaced it?

The water would go into the # 4 cylinder cause it's the closest to the water exhaust.

I have seen heads get warped also from extreme overheating.

Me my moneys on the manifold.

Re: 2002 volvo 3.0GS water ingestion #4 cyl

You know i seen this same problem before here. The manifold have a slight crack and you can't pressure test for it, opens up when it gets hot. And water is constantly going into #4 and it has to miss. Plug is always wet i bet.

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It's possible to pressure test a manifold on a 3.0L He also stated he did, and even did it hot.

The water would go into the # 4 cylinder cause it's the closest to the water exhaust.

Click to expand...

Not if the valves aren't open. If the engine sets level, the water would go into the OPEN valve, no matter what cylinder.

I have seen heads get warped also from extreme overheating.

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He had it resurfaced. Should cure any warp problem, wouldn't you agree?

Re: 2002 volvo 3.0GS water ingestion #4 cyl

i did set the timming with the est shunt, book call for -1 degree (+ or - 1 )degree
the exhaust manifold had on bench, made block off plate between riser and mfld, pressurized to 40lbs with gearcase pressure tester, then waved torch in exhaust ports to heat and expand? no leak down?
also did this to the engine, with the manifold off. pressurised to 40 psi
with water in block and with block drained, also heated # 4 cyl exhaust
port with the torch
- the exhaust flapper was missing when i took it apart? couldn find it lodged anywhere in the exhaust tube y pipe and removed the exhaust bellows
and didnt find it their either?
this engine has been replaced, im wondering if this problem has been since day one?
any other ideas?
Rob

Re: 2002 volvo 3.0GS water ingestion #4 cyl

answer to question, no it doesnt diesel when shut down
and i have the idle @ 850-900 rpm out of gear on hose
if i lower it any more it has a tough time clearing itself
after decel. i have also retorqued the head and riser hot
Rob

Re: 2002 volvo 3.0GS water ingestion #4 cyl

You might want to do a compression test and a leakdown test. A leaky exhaust valve could cause your problem.

Re: 2002 volvo 3.0GS water ingestion #4 cyl

But it's only #4 that gets water and i have seen heads get " out of Square " And there is no fixing that.

We are assuming, that the head was redone correctly other wise Why is it sucking like a vacuum cleaner only in #4.

And if done right then why test valves for leaks.

Yes i agree do everything Don S says, i'm bowing out, Volvo questions i never post to them but this is a straight 4 they are all the same.

Good luck, truly there is no one better on the planet that can help you than Don.

Re: 2002 volvo 3.0GS water ingestion #4 cyl

the head was done @ flagship, performance marine engine builder.
i also took it off a second time and let them recheck for cracks
or warpage.
im thinking the block is the problem, either the cyl is cracked or pourious
down near the bottom of piston travel just above the rings?
or the block deck is warped past what the head gasket can compensate
for?
i have heard that if the engine has any sort of a miss it will draw water in
# 4 - but i have checked with a timming light, while running
to see if the ign missfires when the engine stutters and it doesnot?
i just have a hard time believing that an engine put into use for marine
would be that sensitive?
any ideas?
i have another 4 cyl older 140 im going to see if i can
try the bottom end to see if it makes the problem go away?
just cant see how it could be any of the head, manifold or riser
due to all that i have replaced and tested.
the manifold would be the most likely, but it tests good??
Rob

Re: 2002 volvo 3.0GS water ingestion #4 cyl

i have the idle @ 850-900 rpm out of gear on hose
if i lower it any more it has a tough time clearing itself
after decel.

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That is WAY too high an idle rpm, and I have never seen a 3.0L that idles that high that won't diesel when shut down. You shouldn't be over 750rpm in neutral. If it has "a tough time clearing itself after decel" then you need to find out why. Carb problem??? Water in the cylinder?

im thinking the block is the problem, either the cyl is cracked or pourious
down near the bottom of piston travel just above the rings?

Click to expand...

If that was a problem, you would see water in your oil, not on top of the piston.

or the block deck is warped past what the head gasket can compensate
for?

Click to expand...

You mean you didn't check the block when you had the head off the first time????

Before you take it all apart again, Drain and block off the engines cooling system and pressureize it to about 15 psi and see if it will hold pressure.

Re: 2002 volvo 3.0GS water ingestion #4 cyl

just another shot in the dark here because nobody has mentioned it... But do you have all your plumbing routed correctly?

I'm also with Don on that idle. You should be able to get that motor to idle at 650rpms in gear in the water. If you can't get the idle that low on even on the muffs then it sounds like you have a fuel delivery problem.