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MAJOR ENGINE REPAIR
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November 8, 2004. Despite the boating magazine covers showing toothy young ladies speeding over the seas on trouble-free boats, the real world isn't always like that. Here's a letter that describes -- without rancor -- what the magazine covers avoid. Normally, we avoid these what-went-wrong stories, not because we want to sugar-coat boating, but because after a short time they get tiresome. Something about this letter made it an exception, so here it is.
--Bob Hale
We had a major engine problem this season when the relatively new diesel on our 35-foot sailboat refused to start in the Bodega Island anchorage in Nootka Sound. We are in our 70s and were cruising on the West Coast of Vancouver from our home port of Portland. The engine had been running very well and had been hard starting only on the morning before it quit for good. The engine had only 600 hours, replaced in the fall of 2000 by the engine dealer in Portland Oregon.
Because of the sudden nature of the problem we sailed with the help of our dinghy outboard to the Westview Marina in Tahsis and proceeded to attempt a repair. We thought, at first, that something simple would be found and with possible local help, we would soon be sailing away. After a week of attempts we were still at a loss and took a float plane to Tofino and home for a prior commitment and getting our grandson back to his home.
During this first period we had great support and help by Westview Marina and Hugh Brock, a diesel mechanic from Portland. The Portland dealer that installed the engine did not have technical help available during the day, and call backs did not work out. Altech Diesel in Campbell River, on the other hand, was very helpful, including home telephone numbers for technical help on evenings and weekends.
After two weeks at home we returned to Tahsis with a new resolve and a used 18 hp Evinrude to provide power should the diesel not work out. A quick fix on the diesel didn't work, so with the outboard hooked up we headed for the narrows. The outboard quit at the narrows, so with a very light wind and a foul current we attempted to continue. When the wind quit we went to the dinghy (4 hp) that stalled. Then in my excitement I pulled its starting rope out by the roots. So a quick 180 and three hours later we made our way back to Tahsis. The solution would be to get the diesel repaired by hook or crook and then back to Portland.
With the best local advice we continued with Altech Diesel in Campbell River, first sending the engine head, then pulling and sending the entire engine to Campbell River. The day before we decided to pull the engine, friends Jack and Lucy Mitchum sailed into the marina. With Jack's help we got the engine on a truck two days later.
The greatest hindrance to getting the engine fixed were delays in getting parts and general Murphy's Law. I had applied for an insurance claim on the problem and even though the engine was sent to Campbell River on a Friday the surveyor would not allow work to proceed until the following Thursday. The engine had been built (assembled) using other manufacturers' parts, and replacement parts were available only through the assembling company. The injectors, for example, had no identifying numbers.
With the builder in the States and a newly appointed distributor in Canada, the parts typically took two weeks to arrive. The Portland supplier said they could get parts in one or two days, but would not drop ship. So in addition to two premium shipping charges, we had the added time for shipping, the time for Canada Customs, and the time it took for communications. We let Altech order the parts.
The end result was the engine back in the boat and running after a total of 10 weeks from the initial problem. What caused the problem? We still don't know. The injectors have been rebuilt, the heavily carboned valves have been replaced. The piston rings were frozen and had to be replaced. The Portland dealer says the engine was practically new and this shouldn't happen. The insurance company says the mechanical breakdown isn't covered. The engine had been well maintained and premature failure after the warranty period is just tough luck. Total costs so far exceed to cost of the new engine and its installation.
What would we do differently? Not much, except to get Altech Diesel involved earlier.
The good points:
Altech Diesel in Campbell River. A good shop, and very helpful.
Westview Marina. A super place. Thanks to Cathy, John, Aaron, Scott, Jude, Bianca and the rest. This is the place to be stuck for 10 weeks.
The people of Tahsis, sympathetic and friendly. We like them and even their dogs.
The bad points:
Consider availability of spares and service before picking an engine.
Seeing the days get short when we would rather be sailing.
Burl Romick
SV Wind Song
Portland, Oregon
Prior to posting this letter, I called John Flaherty, who does the mechanical work on the Waggoner boat, Surprise, and asked what he thought of the insides of Burl's engine. John said that one possible cause could be not running the engine hard enough. This could be because of a wish to baby the equipment, or because the engine is too powerful for the boat. It's essential to run enough fuel through the injectors to keep them clean. I don't know if these possibilities apply in this case, but it's good advice for us diesel engine owners anyway.
--BH
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