Perkins 4.108M DIY Rebuild -- A Narrative - Page 2 - SailNet Community
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post #11 of 268 Old 12-12-2012
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Re: This Ought to Keep Me Busy...

Some people will simply do anything to save a few thousand bucks.

Lessons learned are opportunities earned.
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post #12 of 268 Old 12-12-2012 Thread Starter
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Re: This Ought to Keep Me Busy...

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Some people will simply do anything to save a few thousand bucks.
Well, almost anything...
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post #13 of 268 Old 12-12-2012
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Re: This Ought to Keep Me Busy...

Make sure you get the better 'rope' seal for the rear crankshaft seal.

eg Perkins 4.108 rear crankshaft seal - £9.60 : Parts4Engines: Perkins Diesel Engine Overhaul Kits and Spares
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post #14 of 268 Old 12-13-2012
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Re: This Ought to Keep Me Busy...

More pictures of the teardown and rebuild!!!

S/V Jendai
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post #15 of 268 Old 12-13-2012
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Re: This Ought to Keep Me Busy...

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So, glutton for punishment that I am, I've started a winter project:

[IMG][/IMG]

That's our aux -- a reliable Perkins 4.108M that (as you can tell from the staining) has developed a bit of an oil leak problem that is even high by Perkins standards. We also were getting a pretty noticeable exhaust stain on the stern, which didn't indicate good things...

After a lot of deliberation about whether or not to repower, I decided to bring this lump home to tear her down and see just how bad is is. I'll do a complete inspection, measuring the components against workshop manual specs, to see what all needs to be replaced.

At this point, I figure that at best I can get by with a top end job. If the cylinders liners show significant wear, then those'll need to be replaced.

The deal breakers will be if the block, crank, head or other major components need to be replaced.

Stay tuned...

What fun!
Your problem is the color. REAL diesel engines are supposed to be grey. Paint it grey and it will start running again.

HEHE!

Sounds like a fun project. Can't wait to see it.

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post #16 of 268 Old 12-20-2012 Thread Starter
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Re: This Ought to Keep Me Busy...

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Your problem is the color. REAL diesel engines are supposed to be grey. Paint it grey and it will start running again.

HEHE!

Sounds like a fun project. Can't wait to see it.

Brian
But Brian, I thought that the accepted wisdom is that blue makes it go fast?
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post #17 of 268 Old 12-20-2012
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Re: This Ought to Keep Me Busy...

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But Brian, I thought that the accepted wisdom is that blue makes it go fast?
A blue STRIPE under the rub rail makes it go fast. Not the color of the engine. How silly. You can purchase your blue stripes directly through Catalina Yachts. Let me know if you need the number.

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post #18 of 268 Old 12-20-2012 Thread Starter
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Re: This Ought to Keep Me Busy...

Perkins 4.108M: The Teardown

Disclaimer: Not too many pics here -- greasy, grimy hands and digital cameras are a bad combo.

I took my time disassembling the engine, giving all of the parts a first-pass cleaning as they came off to get the majority of the grime off. I kind of used a wide variety of cleaners, together with brass, stainless and regular tooth brushes. Spray Nine did a god job on light dirt. Purple Power was a little better, but plain old mineral spirits was probably the most effective and gives the best bang for the buck. For cleaning non-threaded fastener openings, I bought a cheap gun cleaning set from Wal-Mart; the bore brushes included work well for holes up to 3/8". For the larger holes I laid on a set of pipe cleaning brushes from the plumbing section of Lowes. For the nooks and crannies I broke out the dental tools.

I hit all threaded openings (and fasteners that were still in good shape) with thread chasers.





Each assembly went into its own ziplock bag, complete with fasteners. Those assemblies that were too big for bags were wrapped in packing stretch film. I gave all the iron parts a quick wipe down with ATF or WD-40 first to keep rust at bay until the engine goes back together.



Getting the cylinder head off was a bit of a struggle. I had to use some wooden door shims between the block and the head to get them to come apart. Once the head was off, I saw why. Several of the studs had developed a decent layer of rust, which kind of jammed things up.





All in all, I only had to hit a half-dozen or so fasteners with heat to get them out. The cheapo propane torch definitely came in handy. A couple put up real fights, but they eventually came loose. Repeated applications of PB Blaster, heat, and perseverance eventually won the day.

Several of the head studs are getting a little pitted...



Some of the fasteners are just not worth saving. Here's what most of the bell housing studs looked like. It'll be much better/easier to just replace them.



Getting gasket residue off is time consuming. For small parts that came off the block, I chucked a brass brush into the drill press and let the machine do the hard work. For the bigger parts, it was a combination of tools: a putty knife I put a chisel point on; utility knife blades; safety razor blades; and an old putty knife blade I had sharpened like a card scraper.

Clean mating surfaces:



The broken damper plate bolt eventually came out. Initially I drilled a hole for the easy out only deep enough to get the threads to bite, then let it soak with PBB. No joy... Heat, then more PBB and soak a couple of days; still no joy. Eventually I drilled completely through the length of the bolt so that the torch flame would get heat to the whole part -- JOY!



Next Chapter: Measurements
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post #19 of 268 Old 12-20-2012
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Re: This Ought to Keep Me Busy...

Nice work, and well-written, porf. Hopefully this will demystify the process for folks who think the internal combustion spinnaker is a box of black magic.
+1 on PBB- it's like Frank's Red Hot around stately jones manor.

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post #20 of 268 Old 12-20-2012
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Re: This Ought to Keep Me Busy...

Great post, Porfin.

Ron

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".. there is much you could do at sea with common sense.. and very little you could do without it.."
Capt G E Ericson (from "The Cruel Sea" by Nicholas Monsarrat)
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