Engine Troubles

Yesterday work began on the maintenance of the SABB 2G engine. Zee the mechanic reported oil leaks through the tappet cover and head gaskets.

Reg Kelly had noted the evidence of a head gasket leakage in Fremantle shortly after I purchased the boat. Howver, the maintenance people in Fremantle and New Zealand did not make an issue of it. But it does appear that the problem has gotten worse because Zee pointed out material oozing out through the gasket as the engine ran.

Zee attempted to tighten the head bolts but said that they were already at 120 ft-lbs and that it appeared that somebody else had already been in the area trying to stop the leak.

He fixed the tappet cover leak problem by making a new gasket.

Also, the primary fuel filter case was badly corroded (Mark said that it reminded him of something out of World War II.) and we replaced it with a beautiful new Racor 500FG2 that has been sited next to the engine for easier inspection and filter change. The Racor is the white object at the left in the accompanying photo.

I then had a discussion with Mark, the principal of the company, about the head gasket leak. The best case scenario is that they remove the head, skim it, replace the gaskets, and we live happily ever after. The worst case scenario is that they have to go deeper and deeper due to corrosion and ultimately do what would be basically a top end engine rebuild.

The issue is parts. Mark will not start any work until he can be sure that in the event of a worst-case scenario parts can be obtained. I have sent a description of the parts required to SABB in Norway and New York. If not all parts are available we have a show stopper. Otherwise I will probably order the head gaskets and have them fitted when I return to Port Townsend in early September, and be ready to order other parts if they are required. Zee says that the full top end job would take only about 3 days, done in situ.

I asked Mark if the engine would be worth saving. His reply was a definite yes. The rule of thumb is that a new engine would cost that amount again for the installation (for a total of about $15,000 USD). A rebuild, even with the high cost of parts, would be cost-effective. Mark noted that all of the channels through which the cooling salt water passes would be replaced, which I found very attractive.

Do I need this? No. Am I tired of spending money? Yes. On the other hand, I can't risk an engine failure down in the wilds of Patagonia. Also, SABB's are much better known in the USA than in Australia. Zee says that they were being sold in the USA well into the 80's. He knows the engines well and thinks that they are great. He also thinks that it was rising emission control standards that killed them off in the USA. There is logic in doing the work here.

This realizes an anxiety that I expressed to Brenda a few days ago while I was knocking on wood: that the only major part of Pachuca that I had not worked over was the engine. I guess I didn't knock on that wood hard enough.

... Like the wise man told me many years ago, with boats you pay now or you pay later but you always pay.

On the brighter side, the engine and transmission have had their oils and filters changed. The fuel filters and the zinc anodes have also been changed. They are now in a fully maintained state and the engine starts and runs beautifully. No water has been found in the oil. Zee commented how the effective the cooling is at present. (Question: is it all good enough to get me back to Australia?)