Good questions. I'll try to answer
Re: Eric's 5416 Rebuild
So here goes with my questions:
[I]Now that you are all done what condition do you figure the engine is in now? Good for another 20K hours, effectively new again?
I think it is as close to new again as I could get. I wanted to replace or restore all the surfaces that showed wear and tear or damage. The only major component not changed out or machined was the camshaft, because it checked out ok dimensionally and had no significant damage.
As for how long I expect it to last?, I have heard on this forum people wiser than me give time-between-rebuild intervals between 1k and 5k hours. Given that this engine had accumulated about 1K hours in 33 years, that sounds reasonable.
The machine shop guy you found was he a marine diesel guy or automotive gas guy?
Automotive. Mostly gas. Jensen Automotive in Ogden, Utah. Carl runs the machine shop side of the business. Welcome to Jensen Auto Service, providing auto repair services in Ogden, UT.
Were there people you talked to that you wouldn't couldn't use? Why?
IOW what exactly are you looking for in a machinist?
I knew of one other in my local area. I had used them twice, once I was very pleased once I was not. I asked the mechanic at the local Kubota dealer who he recommended and he told me he had always had good outcomes with Jensen and had been using them for many years. I also asked some auto mechanics about them and got good recommendations.
I visited Jensens and talked with Carl. The shop was clean, well organized and Carl simply gave me confidence that they knew what they were about.
Am I right is figuring that if the engine was not rebuildable you would have found out fairly quickly?
What for example would cause the engine to be trashed?
Good Question. I can't think of something specific. Maybe if the crank was cracked and could not be repaired and the cost of replacement was too much, or something like that.
My logic went like something like this - I had several options: 1) rebuild for a bit over $2K; 2) Buy a used engine (there is one up for sale nearby for $2500 that the owner has rebuilt); 3) Buy a used block from a rebuilder for $4K with warranty; 5) Buy a new engine (eg Beta for about $8K) plus the cost of modifying the engine beds etc. I visited the Beta dealer in Sausalito, CA while I was there and they seemed very helpful and knowledgeable about repowering and were happy to crate and ship a motor to me.
Rebuilding or a new engine became my best choices as only those two meant I knew exactly what I was working with when done, plus, by rebuilding I know the engine inside and out.
The engine did not come with the head. I would have no idea where to look for a replacement head, how did you go about that?
I get that you removed the engine but did you then disassemble the whole block, removing, cylinders, crank shaft etc? and just give your machinist a box of parts?
Thats exactly what I did
I'm assuming you found some kind of shop manual for the engine to know all the clearances to give to the machisist, is that right?
Yes, the 54xx series of engine service manual has all the dimensions needed, it's readily available as a PDF from many sources on the internet. I gave Carl at Jensens a hard copy and emailed him one too.
Did you source part locally, or use an internet source, if so who.
Sunset Kubota locally, Sean its the parts guy. All he needs is the Kubota block type and serial number, both stamped on the block.
online. Their website is slow, but works. I am sure there are many good sources online.
If you had to do it over would you do anything different?
I would not spend the time that I did messing around trying to get the engine to run WITHOUT tearing it down first. I would just get into the total rebuild mode right away.
How long ago was this project?
Pulled motor in June, re-installed in September. I was not in a big hurry, July and August is not my favorite time to sail in the Great Salt Lake, too hot and buggy, not much wind most of the time.
Who assembled everything? If you did how did you know or learn how to do it?
I did. I am not a mechanic, but learned to fix cars as a teen when my uncles were into car racing and needed pit crew.
Did you start the engine the first time. What was that process like.?
I had made a wooden dolly for the motor, which was attached to it with lag screws. I hooked up a battery to starter and glowplugs. Used a 5 gal diesel jug as a fuel tank and put the water pump intake into a bucket that I kept topped up with a garden hose. I ran the engine for maybe 2-3 hours before reinstallation. I have a short video of it running like this. If I can figure out how to post it here I will.
Thanks for the questions. I'll be happy to try and help anyone who is working on one of these engines. I really don't know much about any other diesels as this is the only one I have ever worked on except for simple stuff.