Last night I wrapped up the solar panel installation, and I have to say that I’m pretty pleased with it. Not that it’s a difficult job. In fact I’d now rank solar panels as the number one easiest major update a do-it-yourselfer can make to a boat—and cheap too, compared to most boat projects. I hate working with wiring, but solar panels only require one set of wires running from the panels through the boat to the controller/charger. From there another set takes the now regulated voltage straight to a battery. Simple. All the panels are just piggybacked together one to the other. And just like that we’re pumping 20 amps or so per hour into the batteries. Solar power—black magic.
So a guy from the shop that did the check on the head came out today to have a look at the block as well. He brought along a heavy steel rod a feeler gauge and a light to have a close look for any dips or depressions. The mechanic and his helper were there as well. Nobody is happy about the state of the top of the block. And by that I mean that they aren’t happy that my mechanic in San Carlos didn’t clean it up before installing the head gasket. The surfaces of the head and block need to be spotless, as even the tiniest imperfection can cause problems. This new guy also had a look at the gasket and then had a long conversation with the mechanic. They both agreed it didn’t look like it had been compressed.
So basically there are two theories at the moment. One is that there was simply some imperfection on the top of the block. And the other is that maybe one of the head bolts simply didn’t get cranked down all the way, i.e. something blocked it up so that it felt tight, but wasn’t actually all the way tight. They spent some time running the bolts in and out clearing out any rust, and they also said that they were going to use washers on the bolts just to be sure that they were getting tight and not just hitting bottom (if you know what I mean—if you don’t, I’m sorry but I can’t explain it any better).
Here is the before and after from today. Tomorrow we put it back together again.
The weather has turned here. It’s getting downright cold. I wore jeans today for the first time in I don’t know how long. The jeans are acid wash and sit just above my belly button, which should give some indication.
27 Comments on “Solar Powered Up”
Yes sir…no doubt now…it was your gasket prep and possibly torque as well. You will be good to go when the job is done right.
Solar panels are fantastic! Easy install, work for years…we fitted an MPPT when our charge controller gave up as it is far more intelligent and even increases your power input by up to 30%. If you find you still need more power for the hungry fridge try upgrading the charge controller…worked for us.
So basically there are two theories at the moment. One is that there was simply some imperfection on the top of the block.
Yes, this is a possiblity, but standard mechanicing practice says this should not be.
And the other is that maybe one of the head bolts simply didn’t get cranked down all the way, i.e. something blocked it up so that it felt tight, but wasn’t actually all the way tight.
Not likely, diesels run at extremely high compression, they have no tolerance for head gasket problems. The head was torqued down enough to contain the compression so it would have contained gravity fed water one would assume.
Most likely one of the following. Either
wrong head gasket or the block is porous, most likely through corrosion internally.
Fuss,
The head gaskets have built-in “Aluminum Crush Rings” to achieve compression seals around the cylinders. These rings can achieve a compression seal while still not having enough pressure to make the seals around the water passages water tight.
Pat, you’re no doing a good job selling me on the carefree boat life.
Dude, I assure you I am not trying to sell you on this. There is nothing carefree about the boat life.
Pictures of you in your acid washed jeans, please. 🙂
Hate to say it, but you’re still chasing your original coolant problem you had before tearing the engine down. The “before” picture above looks just fine as far as prep, I don’t think you’re previous mechanic was negligent. I might have also draw filed it which is what your “after” picture looks like. It looks to me like you’ve got a cracked block. There are ways to locate it by using plugs and regulated air pressure, but the reality is even if you find it a repair would be spotty and not something I’d go to sea with. I don’t know what a short block will run you, but I think that’s the direction you’ll end up in the end. I also sincerely hope I’m wrong.
My thoughts as well… Looking at the block pictures and the fact that 2 mechanics saw no head gasket damage. Only amatures would leave oil in the stud holes and not check that the bolts dont bottom out.
The problem is not in the head gasket.
How many Ford Lehman head gaskets have you guys done? The top picture is NOT a good prep surface…not by a long way. In fact, the second picture is still questionable.
Sounds like you have got some competent mechanics working the problem. They are absolutely correct about those surfaces needing to be spotless! They are machined to very tight tolerances and must be free of contaminants so that the gasket can mate perfectly with each surface. Their reasoning is sound and I think you are on your way to a working (non-leaking) engine!
My .02..not re torquing after the install 80% chance it was the issue, 15% bad block surface or crap on it and 5% block has a crack/hole someplace..
PS +1 on the solar..reminder to clean them ever day!!! or at least every other day. Slat air leaves sticky stuff every night..and dirt sticks to it quickly…very small amounts of dirt/dust reduce output.
if they use washers make sure they are very good quality hadend washers
stan
Before doing the washers, get them to check there was actually a problem with the bolts bottoming out. Measure the depth of all the holes and measure the thickness of the head at each bolt hole and then the gasket. You with then know wether this was actually a fault. If there is enough tolerance then this senario can be eliminated.
Adding washers just adds more uncertainty, was it the washers that fixed it or the cleaned up surfaces, you will never know.
Also check that the bolts actually screw in that distance. Engine diagnostics is about measuring and checking.
I would look at head studs. Re-useable, though you hope not to need to pull the head any time soon again. But no chance of bottoming out, and better to torque and the torque to yield bolts. I would also look at the copper head gasket spray as a little extra piece of mind. Good Luck!!
Bill said that they sometimes actually mill the top down because it can be warped just a hair, causing everything to be off.
Your engine is driving me nuts Pat. I’ll sure be glad when you fix it.
Good luck
Lots of guesses here, and really, we won’t know until we know, so it doesn’t really matter at this point.
We’re installing the head first thing tomorrow.
Here’s my guess… if the jeans come up over your belly button, maybe they’re Ali’s … 🙂
I’ll buy you a pizza if this is not the fix.
If the head has been machined, either most recently or in the past, those roll pin holes may not be deep enough to take the full length of the roll pin. This would result in the head hanging up after you torqued it down. Check the head bore corresponding to the roll pin for signs of bottoming.
For what they’re worth, just replace them. The one on the right doesn’t look good.
The good news is you’ve found your problem – bad head gasket installation. The bad news is that the top of the block in the “after” picture is not ready for a new gasket. Still needs some work or it will just take a little longer to leak than last time. Don’t put washers under the bolts. If the bolts are bottoming out and you can’t clean out the bolt holes in the block, shorten the bolts slightly rather than using washers. Neither option is great, but slightly shorter bolts is safer than washers. Either way you get the same length of thread screwed into the block, but the effect of washers on the torque/gasket compression over time is too unpredictable.
Agree with the “after” picture statement.
hey,
the white engine bay in the background looks sweet. presentation is everything !
fd
Good luck on the engine.
Yeah sorry we missed you in Mazatlan. We decided to head for San Blas. Got there and had no bugs. None for 48 hours. Spraying for dengue? Quarter moon as told by the river tour guides? No matter. No bugs. San Blas rocks. Even with bugs we would have loved it.
In PV now. You guys leaving anytime soon? ;).
Sam is having fun with a 5 year old here and of course Cora.
Best
Marcus and Jennifer