Engine disaster -- July 7 to Sept. 8

When we last wrote about our adventure, we had returned on June 29 to Tidewater Yacht Service in Baltimore with a very serious engine problem.    We had moved some of our gear back home where we would wait out the repair.    Anyway, once the mechanic begin working on the boat, we could  not be living on the boat since the engine space would need to be accessible.

We were very hopeful that work would start as soon as possible but the 4th of July holiday added to the delay.

On Friday July 7 we got word from Tidewater that they had been researching our problem with the help of the Yanmar distributor and they were planning to test the oil cooler first which is not very difficult or time consuming.   If that tested OK, then they would have to address the possibility of a blown head gasket.   That would involve removing the engine from its mounts and lifting it up and out of the boat to gain access to the components that were involved.   That was a possibility we dreaded to even think about.

On Thursday July 13 the mechanic finally began working to remove our oil heat exchanger and oil filter assembly -- they are mounted together on the engine.   In the shop he built a test apparatus which pressurized the coolant side with soapy water to 35 PSI.   The oil filter had been removed and the oil filter assembly was empty.   However, a fine stream of soapy water was entering the oil filter through some cracks or defects that SHOULD NOT BE.  Replacement parts were ordered and we paid extra to have them delivered by next day.

Testing the oil cooler assembly

On Wednesday, July 19 the new parts were ready to be installed.   This went well and by the end of the day the motor had been run at the dock and the coolant filled including the in-cabin heater and domestic water heater which are extensions of the engine cooling system but are located remotely.   I cleaned the coolant recovery tank and left it completely empty -- the engine coolant is supposed to expand into the recovery tank as it warms.

On Thursday July 20 I was getting ready for a sea trial.  It was oppressively hot and forecast to be around 100.   Barbie joined me for the sea trial.    We had a nice trip, running the engine at high cruising  3000 RPM toward the Key Bridge and then turning toward the inner harbor and running slowly because they have a 6 MPH speed limit in the harbor.

It was a very enjoyable cruise.  However, when we arrived back at the dock we saw some problems:  The coolant overflow tank had overflowed and there was engine oil in the coolant.   Filling the coolant next morning, I added about a quart.  We were very concerned and discussed the situation with Tidewater.

On Wednesday July 26 we took another sea trial with just Jeff and Barbie.   This lasted only 9 minutes operating first five minutes at  2400 RPM and then 4 minutes at 3000 RPM.    Jeff opened the hatch to observe the coolant recovery tank.  It was full and spurting coolant through the tiny vent hole in the cap.

Coolant being forced to overflow reservoir

On Thursday we discussed the situation with TYSC. They said that a leaking head gasket would explain the current situation.    We returned to the boat and unloaded all of the perishables such as beer, coffee, dog food and any food it the refrigerator and the freezer.   Now we are prepared to have the engine worked on with major repair.  They will probably have to remove the engine because there is little room to access it while in the cramped engine room.

Tuesday, August 8, 2017
We received a message from Tidewater and it was bad news.  They had removed the engine and placed it in the shop. They disassembled the engine head and inspected the head gasket and cylinder walls. I arrived at Tidewater the next day to survey the damage.

The head gasket was OK, but the piston cylinder walls had unusual wear.   Most  importantly, there was a 2 inch long thin crack in cylinder 3.   Our mechanic said we would need to find a "long block" which is a new engine block and head assembly.

Tidewater contacted the US East Coast Yanmar distributor, Mack Boring Parts Company, and found that our engine is not made any more and no replacement blocks are available. On my own, I started to check for the parts we would need for repairs. I contacted Mack Boring on my own, plus I contacted engine service companies in Annapolis and New Bedford, MA.    There was a positive response from Niemiec Marine in New Bedford.   Although they were not available in the US, Niemiec could obtain a new engine for us from Canada.   We received a detailed quote for new engine and the labor to install it.  The price was reasonable as far as could be expected, but very expensive none-the-less.  We had few choices: different engine (wouldn't fit the space), no engine (useless boat), sell this boat as-is (who would want it?) -- We decided to go with Niemiec which is an ideal shop for engine replacements since they do this type of work very often.

Friday, August 11, 2017

We went to our credit union and withdrew the deposit money.  This was sent to Niemiec by UPS messenger envelope. This covered the cost of the engine but not the labor to install it.

We researched transportation for getting Aisling to New Bedford. It would require a hydraulic trailer which can load a boat while it is blocked and supported by stands.  We went with a company recommended by Niemiec.  They would be able to pick up the following week and deliver next day.
They would need to transport our old engine as well.  That old engine would be needed for the boat-specific parts to successfully install the new engine.

Saturday, August 12, 2017

We started preparing Aisling for the truck transport.   First we removed the dinghy from the stern and brought it home where we folded it up and stored it.

Ready for transport by truck

I took off the Bimini top and took it home to fold it.   It is back onboard and stored in the v-berth. The bimini frame is folded and taped together to keep it from shifting in transport.  The anchor on bow is lashed firmly on the deck.   Also the anchor on the stern is lashed firmly and the chain lashed into its small basket on the swim platform.

Tidewater started to prepare the old engine on a pallet with the associated parts in boxes or securely shrink-wrapped in plastic bundled with the engine.

Wednesday, August 16, 2017

Our transport company picked up Aisling on Wednesday and delivered her to Niemiec the following day.  Meanwhile our new engine was being shipped by truck from the west coast of Canada.  We expected it to arrive by Friday, August 25 but  it was delayed and arrived Thursday August 31.

Friday, September 1, 2017

Niemiec Marine had already removed the transmission from the old engine and refurbished it by removing surface corrosion and with new paint.  They began working on the engine for installation in the boat.

Friday, September 8, 2017

Today we received the news that the work is almost complete with just a few details to work out.   Next week we are preparing to rent a car one-way from Baltimore to New Bedford.  We will take the items we removed from the boat, plus our dogs Hans and Greta.   When we get there we will take Aisling for a Sea Trial.  If that goes well, we will start living on the boat while docked at Niemiec Marine.   After a few days of that, we should be starting out on our journey.