Engine oil leaks

As of the close of the 2012 season, the engine leaks oil - both lube oil (way too much) and fuel oil (more than we'd like). The plan during the early spring push is to deal with all these problems and more:

Lube Oil leaks

We will be replacing both the front and rear crankshaft oil seals on the engine. The front seal seems pretty easy and straightforward; the rear seal will require dismantling much of the exhaust system, removing the transmission, flywheel cover, engine flywheel, and other pieces. Oh, the rear engine mounts are part of the flywheel cover, so we will need to elevate the engine. This process was documented by another sailor at [1]. Parts (mainly gaskets) are available online from a vendor in England ({http://www.parts4engines.com/index.php?main_page=product_info&cPath=39&products_id=263&zenid=cbb906f8c5b0468c8f2444df6e3a4999]) or from Foley Engines in Worcester, which seems a specialist in Perkins 4.108 engines[2]. They have so far been unresponsive to price quote requests; I am persistent and will get the quote (and likely the parts) from them.

It might be the case that the real leak is not caused by the front oil seal but the gasket the for the timing cover; this will be replaced as well.

Fuel Oil leaks

Both the lift pump and the injector pump leak. The lift pump is 'easy' to get at and will either be replaced or rebuilt. Replacing the requisite O-rings in the injector pump is best done by removing the heat exchanger, and at the moment that is the plan. This will also allow us to change the orientation of the cut-off lever so that we can pull the T-handle to shut off the engine.

Filters

The lube oil filter is in a difficult spot, and is next to impossible to replace without dumping a fair amount of dirty oil over the engine an into the bilge (the design requires the removal of a metal bell; the filter is a paper cartridge inside). The primary fuel oil filter is accessible at the bottom of the stbd cockpit locker, close to where the ends of the emergency tiller bang around. The secondary fuel oil filter is much like the lube oil filter, inconvenient and messy (it's not been changed while MIT has had the boat). I'm going to replace the lube oil filter with a standard spin-on unit in a more accessible location. The two fuel oil filters I'm going to move so they are accessible from behind the steps inside the cabin, and replace the secondary fuel oil filter assembly with one that has a spin-on unit with a clear bowl at the bottom (complete with a drain valve), The time I've been on a boat where the diesel engine has failed was due to fuel contamination.

In addition the usual pre-season things will be changed, like the raw water pump impeller, filters, etc.

I believe that in the end we will have a reliable engine that is leakless (ha!) and will be much easier to service should the need arise.

Other things that would be nice but not necessary:

• Relocating the lube oil stick. This can be done in theory by bending the tube; there may not be a better place to put it.
• Removing the engine from under the stairs to perform these tasks. This would make everything so much easier but we'd have to build special rigs to make it happen. We'd also have to assure that the alignment with the prop shaft is replicated when we put it back.
• Having the fuel injectors cleaned. This would seem to be the right time to do it; we'll be removing much of the injector plumbing. Nothing seems wrong with the injectors, though.

The parts list (i.e. what I asked Foley to quote a price for) - the parts numbers are from the engine parts list on the wiki ([3]):

• The Foley replacement rear oil seal - replaces 36883115 Seal - rear end oil (set of 2)
• 36826114 gasket - REOS housing (might be part of your kit)

• 0730098 seal- front end oil
• 36813145 gasket - timing case
• 36826122 gasket - flywheel housing
• 36867115 gasket - flywheel housing
• 36857107 gasket - flywheel housing
• 0490724 gasket - cyl. head cover
• 36862517 gasket - oil filter head
• 0500006 woodruff key for pulleys on crankshaft
• 0490656 gasket - exhaust manifold (2)
• 24860167 cover (rubber cover on end of water heat exchanger/exhaust manifold)
• 24865264/24860166 cover (rubber cover on end of water heat exchanger/exhaust manifold)
• 0490785 gasket - water pump
• 0460038 impeller - water pump
• 0730110 plug - water pump
• 36821503 gasket for mounting raw water pump on timing cover adapter plate
• 33825411 (need 2) - gasket for mounting raw water pump on timing cover
• 3685R008 gasket- lift pump (4 bolt)
• U5MK0160 repair kit - fuel inj pump (we are only looking for the o-rings for the throttle and cut-off spindles of the hydraulic version; don't have separate part #s)

• 26410087 repair kit - lift pump (should be for 4-bolt version)
• A replacement 4-bolt lift pump
• (we will get one or the other)

• The Foley spin-on secondary fuel filter adapter kit

• The Foley lube oil spin-on filter adapter kit