Engine re-build - Detroit - Desicion made - Start 03 Nov 2011

[Divemaster1]

Those who read the story about our holiday this year, know that we have a piston failure on our port engine.

http://www.ybw.com/forums/showthread.php?t=284048

After continuing the use of our boat during the weekends left in September and last week-end in October, dolphin watching etc.... but mostly de-stressing after bid rounds, more solution proposals across europe (and some contract wins), we have concluded that it is time to start the work getting down to the nitty-gritty of replacing cylinder liners, piston etc.... whilst in the water.... once the next proposal round finishes in a week or so...

So booking time off work for a couple of days to take the camera with me and start getting clear access to engine (seating arrangement removal) and starting to remove the bits (Exhaust manifold, Turbo, Intercooler Coolant header tank, thermostat housing, fuel & oil filters,oil & oilpan, Rocker cover etc.) which I need to remove to have clean and open access to lift out the 110 Kg Cylinder head to get access to teh cylinder and broken piston crown. The oilpan removal should give me clean(ish) access to the bottom end to release and push the piston up and out etc.

Needless to say, I will try to keep a picture log....but it may not belong in here as it probably will be a bit PBO....(should I move this thread there?)

More to follow in a couple of weeks when I know more about the challenges encountered.

 

[aquapower]

Keep it on here, keep us posted with as many pictures as you can.

Good luck and hope all goes well.

 

[vas]

Keep it on here, keep us posted with as many pictures as you can.

Good luck and hope all goes well.

+1

removing the oil pan (that must be the sump in carspeak) do you have enough access to also see the bolts you'll be undoing?
I guess you'll remove the con-rods from the crank and pull the piston rod assembly from the top, right?

good luck!

FWIW, my craft still has the original (I assume detroit) gauges on the lower helm. Look nice and detailed and in good nick. Obviously don't know how well they're working. I wonder if it would be of any use to you or anyone else, as I'll be removing and redoing the helm integrating the IVECO dials which are now bolted on top of the others and they are no use to me...
I'll try to dig out some photos

cheers

V.

 

[oGaryo]

ditto, on here please.. have done similar on cars myself and will be interesting to see the difference in approach

 

[AndieMac]

Keep all "Navigator" issues to her home berth in Mobo Alf, I'll be watching proceedings closely

 

[Divemaster1]

Access...

.....removing the oil pan (that must be the sump in carspeak) do you have enough access to also see the bolts you'll be undoing?
I guess you'll remove the con-rods from the crank and pull the piston rod assembly from the top, right?............

Yup ... and I believe so (but time may tell me different ...). Block is slanted outwards (lower profile that way), so should have clear access to clam bearings at the crank.. All oil pan bolts should be OK, but some are actually accessed from inside oilpan through access panels (due to the slanting engine, oilpan is a bit odd shape) ... and if I am really lucky, I may get access to clam bearings from access panel. Main challenges are to have clear access to remove cylinder head (heavy) and then the question is if I have enough height under deck to remove piston and cylinder liner without having to be cutting into the deck above.

WRT instruments, the DD ones should be OK and accurate, as the RPM is mechanical and need a £15 wire, Oil Pressures are pneumatic, temperatures are wired sensors etc.. All parts easily (and cheap) available... You have your engine room gauges still ??

 

[rafiki_]

Very best of luck.

I have only removed pistons on car engines from below, with the luxury of a pit or lift, replacing them from above. You must have much better clearance below the sump on your engines to mine.

 

[Deleted User YDKXO]

Needless to say, I will try to keep a picture log....but it may not belong in here as it probably will be a bit PBO....(should I move this thread there?)

.

IMHO you should keep the thread on the Mobo forum. I for one am v interested in hearing how you get on. Good luck!

 

[volvopaul]

Im just in the process of doing an engine rebuild on a volvo 61a, I have made a frame to lift the engine from with beam across the top I have lifted it over 15 inches to remove the sump, its been a relatively easy job as the boat has no fuel tanks outside of the engines and has good height above the engines too, I will get andy to post some pics of the job.

 

[mainshiptom]

keep it here

would love to see pictures...

Tom

 

[Nauti Fox]

All the best Alf, when I was taking the heads off mine I was convinced they were seized on the dowels.....they weren't, it was just that they were so bloody heavy!

 

[vas]

WRT instruments, the DD ones should be OK and accurate, as the RPM is mechanical and need a £15 wire, Oil Pressures are pneumatic, temperatures are wired sensors etc.. All parts easily (and cheap) available... You have your engine room gauges still ??

Hm, never thought of reusing them with the new engines. Have to admit the DD ones look better than the Iveco's but the iveco rpm features a small led display for the hours of the engine and I'd not want to loose that. Having a matching set of gauges is helpful as well so looks like I'll remove the DD ones.
Unfortunately there are no e/r gauges. Guess there weren't any to start with.

good luck with the work!

V.

PS. tried to have a look at the old threads on buying/delivering your boat, but all pics are unavailable. Anything that can be done about it? Any photo lib you could share? Since ours and MystereMarcus crafts are very very similar, I'd like to have a look around, not only salon and rooms but mainly helm, engine room, lazarette (sp?) and bow/central bilges. Need to fit a large emergency pump and your layout would help me a lot.

 

[BartW]

keep the photo's on here Alf,
as many as you can, and time allows,
good luck with the job, very interested !

 

[Divemaster1]

.... and so it starts ...

More to follow in a couple of weeks when I know more about the challenges encountered.

03 Nov and being pulled in all directions (good for work, I know... but still wanted to get started), so said that "I'll be working on my boat, but will review documents during the days...".... well, not today that is.

Arrived about 11:00 to a nice day and starting off with a nice, clean boat, which looked OK...

Going from this;

... to this in about one and a half hour.....

Giving quite good access to the port engine;

One hour later, intercooler and air intake is removed (small damage discovered on intercooler and assessment will be made if repair is needed) and oil is being extracted...

Another hour and Turbocharger is removed;

..... and the pile of stuff on aft deck is growing;

...another couple of hours spent at the front of the engine, draining coolant and loosening stuff, but, no pictures yet....

Getting dark, fused light with blown bulb (apparently hot 240V inspection lamp and bulbs don't like 15 - 20L of cooling water pooring over it ) , so decided shower and meal was in order.... so now a glass of wine and posting this stuff.....

 

[vas]

looking tight, how many days to have a nice clean pic of the cylhead (in situ without any manifolds on)?
Doesn't look like it's going to be an easy job lifting the cyl.head.
I guess the bit of floor towards the galley is not removable, right?

(btw, quite similar to my layout...)

V.

 

[volvopaul]

I know where your going alf, yesterday I spent taking heads off 61a from "andydent2000" powles 46 here on the hamble, fitting frame over engine to lift it, then sump off pistons out (the bore wear can be measured in mm not thousands of an inch! in that the top rings struggled to be pushed past the wear lip being compressed into the ring grooves, matched with years of carbon build up in the ring lands.

Then liners pulled out today, and a big tidy up before andys down for the weekend.

Engine overhaul kit , oil pump repair kit and 12 new valves ordered today.

 

[Divemaster1]

Exhaust manifold going off tomorrow and getting ready for a cylinder head liftout... Block angled at about 45 degrees outwards so not a straight up lift, so more space than picture indicates.... but problem is lifting up and outwards, whilst preventing swing..... just as well as DD already have lifting lugs fitted to the head...

 

[Divemaster1]

Yup VP... sump will be a big job as a rght $£%&* to get access to .... but once off, as the block is at 45 degrees life should (in principle) become easier... probably won't work out like that of course...

 

[benjenbav]

Alf, it definitely belongs on here. But if you decide to recover the saloon table with fablon you should put the detaails of that on pbo.

Best of luck with the project.

 

[Nauti Fox]

All the best Alf, I've got a real decision to make as well now
The starboard fuel tank has started to leak, which is outboard of the engine and pretty inaccessible, so this weekend it will be drain it down and rig it so the starboard engine can run and return to the port tank while I consider a plan of action...bloody boats!
All the best mate and watch out for yourself down there.