Rhapsody J/ Yanmar 2GM Engine Rebuild Winter

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Hector Harrington
5 years ago
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1 Rhapsody J/ Winter

2 Why take this on? Rhapsody s Yanmar is 25 years old Pin hole leak in raw water cooling sprayed salt water throughout engine compartment engine has rust spreading like cancer Intermittent overheating exhibited after slowing down from high speeds Vapor lock & fuel starvation problems started this past sailing season The engine does not use oil or blow smoke, so rings / bearings are not needed don t fix it if it s not broke! I can t be sailing this winter, so why not rebuild the engine..

3 Engine Removal and Transport Disconnected shaft coupling, transmission cable, throttle cable, fuel shutoff cable, battery lead, and unplugged 2 connectors on wiring harness Removed exhaust hose, fuel supply hose, fuel recirc hose, seawater cooling hose Engine was removed by 4 people using main halyard run through twing at end of boom to position over main hatch Engine stand built from 2 x 3 lumber was used to transport and hold engine during rebuild (3 man lift) Engine transported in back of SUV, then carried to basement workshop for rebuild This isn t rocket science!

4 Yanmar 2GM Engine Removed Engine Mounts left in place with lower hex nut positions unchanged to make alignment easier when engine is replaced.

5 17 Nov 2006 Yanmar 2GM Engine Before Disassembly Port Side View

6 17 Nov 2006 Air Filter Removed

7 17 Nov 2006 Aft Zinc Plug & Exhaust Elbow

8 17 Nov 2006 Front View Note Rust Spreading

9 17 Nov 2006 Oil Pan from Front & Rear Note there is no drain plug on the oil pan. Oil must be pumped through the dipstick tube. Alternate solutions will be investigated for effective oil changes.

10 17 Nov 2006 Valve Cover & Fuel Injectors Removed

11 17 Nov 2006 Fuel Filter Removed

12 18 Nov 2006 Alternator, Starter & Thermostat Flange Removed Note scale and rust buildup in water passages

13 18 Nov 2006 High Pressure Fuel Pump & Head Removed Note the carbon buildup on valves & pistons is not excessive for a 25 year old engine. More significant is carbonized scale closing up the water passages.

14 18 Nov 2006 Positioning Engine on Elevated Portion of Stand The engine is hoisted using the Cunningham as a winch. Elevating the engine on the stand allowed a puller to be used to remove the crankshaft pulley.

15 18 Nov 2006 Table Arrangement Maps to Upper Engine Location I hope I can get this all together again!

16 21 Nov 2006 Oil Pan Interior No Sludge! There s plenty of clearance to install a drain plug here, but the pan is an Aluminum-Manganese alloy that would be subject to cracking if drilled.

17 21 Nov 2006 Engine Water Passages & Piston Tops Cleaned Left side 1 piston cleaned & 1 carbon covered. Right side both pistons cleaned. Water passages were 75% closed with white scale before cleaning.

18 21 Nov 2006 Head Interface Cleaned & Protected Top of block is taped to keep foreign material out of cylinders, oil passages & water passages. Tape to be removed after painting, prior to bolting on the head.

19 22 Nov 2006 Stbd Zinc Plug Removed / Block Wire Brushed Zinc plug had no zinc connected the zinc was floating free in water passage. The right side is the aft Zinc (new) for comparison. The Block is ready for degreaser

20 22 Nov 2006 Block Wire Brushed Forward and Port Side Views Scale and loose paint has been removed with a wire brush. A chemical degreaser will be applied to clean the surface in preparation for high temperature primer paint

21 3 Dec 2006 Block Degreased & Masked for Painting Transmission painted in 2005 with Clutch Rebuild so it is masked.

22 3 Dec 2006 Block Painted with High Temperature Primer Zinc plug was later installed stbd side after 1 st coat & then primed. Primer has a 7 day cure time before painting Yanmar Gray

23 10 Dec 2006 Block Painted with Yanmar Gray Finish coat sprayed and masking removed

24 10 Dec 2006 Parts Cleaned & Primed Cylinder head cleaned, water passages opened, degreased, masked & primed. Others cleaned & primed: HP Fuel Pump, Exhaust Elbow, Various Cooling System Parts.

25 21 Dec 2006 Preparing Surfaces for Head Gasket Surfaces are masked & sprayed with gasket sealer. Cylinder walls & piston tops are coated with oil to prevent rust. Note significant detail on valves with carbon gone.

26 4 Jan 2007 Head & Fuel System Bolted in Place No signs of rust anymore! Only components left to install are the electrical (starter, alternator, harness), oil pan and the cooling system piping / hoses

27 4 Jan 2007 View from above and parts remaining The electrical components still need to be cleaned, degreased and painted. There aren t many parts left on the table!

with t-fittings to monitor flow through the engine.

28 13 Jan 2007 Preparing to flush cooling system (bypasses Water Pump) Clear plastic tubing connected with t-fittings to monitor flow through the engine. Zincs & thermostat removed with garden hose connections installed

29 13 Jan 2007 Fresh Water Backflush Water forced in block & extracted through the flange by the thermostat. Flow is in reverse to normal cooling. Compressed air used to blow out lines after flushing.

30 13 Jan 2007 Acid flush setup Fill & Drain pipes elevated so the acid (vinegar) can be poured to sit overnight in cooling passages. Bubbles rising in the tubing indicate scale was dissolving

31 13 Jan 2007 Electrical System Cleaned & Primed The starter motor & alternator were cleaned, wire brushed, degreased and masked before priming. Subsequent to priming, these parts were painted Yanmar Gray.

32 14 Jan 2007 Cooling System Plumbing & Alternator Installed After cooling system acid flush, engine was fresh water flushed, drained & air dried. Zincs, thermostat & new hoses were installed. Alternator installed & belt tightened.

harness connected to the various engine sensors.

33 14 Jan 2007 Starter Motor & Wire Harness Installed The starter motor was installed and the wiring harness connected to the various engine sensors. The right picture shows the air filter base mount installed.

34 14 Jan 2007 Top of Engine Completed Engine is complete except for oil pan installation. Views shown from all four sides. The good news is except for the oil pan & bolts, there aren t any parts left over!

35 14 Jan 2007 Crankcase View with Oil pan removed This is a good view looking into the crankcase from the bottom of the engine. Note the oil pickup and the original orange paint on the inside of the block.

36 20 Jan 2007 Final Preparation of Oil Pan Oil pan is masked and sprayed with gasket sealer, along with the gasket. Gasket is placed on clean oil pan and bolt holes aligned so sealer can set.

37 20 Jan 2007 Final Assembly with Oil Pan Oil pan is bolted in place making this the final assembly step of engine rebuild.

38 Quantity Used Description Part Number 2 Engine Zinc Fuel Filter Fuel Filter Bowl O-Ring Thermostat Gasket Water Pump Impeller Water Pump Gasket Oil Filter Fram PH35938A 1 Hose, Pump-Bypath (Water Pump to Engine) Hose, Thermostat-Mixing (Exhaust Spray) Hose, Bypath-Thermostat Yanmar USA Gray Spray Paint Can Temperature Sending Unit Plug, Zinc Holder Plug, Zinc Holder Rubber Washer, Zinc Holder O-Ring, Fuel Injector Insulator, Fuel Injector Cover, Fuel Injector Gasket Set, Rebuild (Includes Copper Washers) Bypath Pipe Connector Racor 2 Micron Fuel Filter R24S 1 Perko Seawater Strainer Cover Gasket 493 DP5 99N 1 Permatex Form-a-Gasket Sealer Parts Purchased Useful Tools & Supplies for Rebuild Yanmar 2GM Service Manual Metric socket set Torque Wrench Air Compressor Denatured Alcohol Dremel Tool (clean water passages) Emery cloth, steel wool Wire brushes (hand & rotary drill) Engine stand (2 x 3 lumber) Engine hoist (used Cunningham!) Wheel puller (for pulleys) Special thanks to Meredith Leblanc from Oldport Marine Services 1 Sayers Wharf Newport, RI Tel. (401) She ll find you any part!

Lubrication system components, removing and installing

17-1 Lubrication system components, removing and installing Note: If large quantities of metal particles or other deposits (caused, for example, by partial seizure of the crankshaft or conrod bearings)