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  • June Project of the Month (Click "x" at right to dismiss)
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B.M.C 1.5 diesel rebuld .

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BRIAN

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#1
Had a bad day yesterday. found the boat engine had fuel in the oil, LOTS of it pumped out 7lt of very thin oil?
it don't look like the lift pump ,its dry in that area but i have fuel in the bilge on the injection pump side ,But cant see a leak?

I don't know how long this has been faulty but I noticed the pressure was low last time out.

I have a few other items that require attention so its time for a rebuild.

So i will be looking for spares I don't know what yet. but best start the ball rolling!!!:thinking:

Brian.
 

BRIAN

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#2
At last things are moving,
As I cannot remove the engine in one piece without dismantling large parts of the boat I have to remove it in manageable parts so the, head -- gear box---flywheel--bellhousing--and all the small parts have been removed.



P1011921.JPG


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Now all I have to do is lift it, slide it sideways into the walkway, then forward into the main cabin.


Brian.

P1011921.JPG P1011937.JPG P1011938.JPG
 

davidh

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#3
looks like a miserable job. did you do it while working on your elbows ? on my old 30 foot chris craft i had to do all my work below my knees while kneeling on the deck. i still hurt when i think about it. this boat looks a bunch bigger. good lluck with your project.
 

BRIAN

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#4
Hi David.
Yes it a real PITA but if you think that was bad, try this, when the engine wants your work space!!!!

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Next thing is to move stairs then move the motor into the main cabin. but tomorow will be a day off.
:whistle:

Brian.

P1011939.JPG P1011940.JPG
 

RLWP

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#5
Just to encourage you...

Our BMC 1.8 head blew last year. I took the head off, checked it over, decoked it and refitted it with a new gasket. We were under way again 23 hours after it failed :)

Well, we had somewhere we had to be!

Lots of spares for BMC 1.5 engines, and a pretty robust unit. That should be a satisfying job

Do watch the heater plugs though

Richard
 

BRIAN

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#6
Hi Richard.
Thanks for the encoragement, at 72 I need all the support I can get. The job its self is easy.its getting to it, thats the problem.
All This hassle because a small oil seal in the injection pump failed.
I will probably change the heater plugs altho i do not have to use them here in the med, But while I have it all apart it seems a wise move.
Today I have been clearing space for the motor in the cabin, moving parts I have dismantled up to the house .
for cleaning and overhaul.
Once I have the engine apart I can write a shopping list.

More later Brian.
 

RLWP

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#7
If they are the very thin ones, and you don't use them, I would leave them alone. If they fail, they develop a lump on the side of the end. When you unscrew them from the head, this lump sticks in the mounting hole and the end gets twisted off. Then it's a tricky job to get them out

Richard
 

BRIAN

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#8
To day I had a go at the heater plugs, I knew Number one was suspect because it had copper washers under the top so I left well alone for 12 years but now I have the head off its time for action.

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As suspected a dead heater and as Richard pointed out the end is stuck in the head.

So I made a bush to align a drill slightly smaller than the element of the heater. and drilled down to the corect depth, and the dead end came out with the drill.

P1011943.JPG

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I ran a drill of the correct size through to clear out the carbon and we now will have 4 new plugs if we ever require them:))


Slowly---Slowly Brian. .


.

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RLWP

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#9

BRIAN

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#10
At last a chance to get to the boat and make progress
Moved all the upholstery into the front cabin, and protected the wood work, then draged the motor into the main cabin, for a swift internal inspection.
Apart from the timeing chain and oil seals and a slight glazeing of the bores the motor is in very good condition. I now have the list of spares I require. the injection pump and injectors are in the shop for repair so things are moving.

P1012014.JPG

Brian.

P1012014.JPG
 

BRIAN

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#11
The next part requireing attention was the heat exchanger, long ago a engineer??? had fitted the injection elbow to the alloy casting with a copper gasket. the resulting electrolisis caused a lot of damage to the mating faces.

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So I set it up on the mill ,A bit of a tight fit!.

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And took a skim to see the damage.

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The strengh of the flange was still ok but the mating face was shot.
So I bored out the bad area.
Made a spacer from a scrap pully.
Bonded it in with Hi Temp epoxy
Then skimed the surface.

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P1012058.JPG


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That will fix it

Brian

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Rbeckett

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#12
Brian,
I used to do that type of work and know how frustrating it is when you find an issue like the copper gasket and all the trouble it causes. I think your solution to the damage is great and should provide many many years of trouble free ops into the future. Is your cooling system a sea water system or does it use a heat exchanger? Looks too clean to be a sea water system, but anything can happen when you talk about boats and seawater. I was going to point out that it looked like the fuel had been running down the outside of the engine under the pump flange but you already figured out where the fuel was coming from. Unfortunately I have a place here in the US that I get to rebuild all of my pumps and spec them out. If you have an issue with you rebuilder let me know and I will forward the info for a reputable pump repairman and facility here in the US. The freight might be high, but I trust the fellow and know he does excelent work on every pump I have ever sent to him for repair or calibration. Good luck and hope the rest of the project goes uneventfully and you get navigating again under power soon.

Bob
 

BRIAN

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#13
Hi Bob

Yes this is a manifold / heat exchanger the big round hole is where the tube stack lives, a far better system. then raw sea water cooling.
I have a good man to do the pump who realy understands what he is doing.
This job is going to take a long time because now the engine is out I am taking the chance to do all the jobs that one normaly cant get to
like a rewire etc. Also fitting a AIS transponder and DSC radio at the nav station.
So along with the clocks and Normal??? life I will be a busy boy.
Thanks for the offer of help its much appreciated.

Brian
 

BRIAN

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#14
The next little job that needed attention was the the fuel filter. It was a real PITA to change. The problem was that when the engine was converted for marine use the oil warning light switch was replaced with a sender unit for a pressure gauge, this made changing the filter element almost impossible, without dismantling the whole assembly.

P1011918.JPG

I did not want to alter the original pipework, so I had to find a new place to tap into the oil system for the sender. Luckily the engine conversion included an oil cooler and the adaptor seemed a good place to do the deed.
So after taking a few measurements the adaptor was put on the mill and spot faced.
P1012308.JPG
The hole was then drilled just under size with a slotting drill. This was because the hole was not going to enter the oil way on centre and I dld not fancy my chances of the drill grabbing.
P1012309.JPG

Then the correct size drill and tap 1/8 NPT.

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Looks OK
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And fits perfectly, the original position now has a switch for a warning busser.

Brian I dont know what went wrong with the photo order but it won't change back. B.

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CS Cruiser

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#15
Brian, enjoyed your posts on this rebuild, how did it all end up?
 

BRIAN

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#16
Ooops went out sailing and forgot to finish the thread.


I will get a few more photos together and do the job, my apologies
thanks for reminding me.

Back soon Brian.
 

Clogs

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#17
HI Guys,
just 2 say I'm a 1.5 fan......my engine has done around 750,000 miles (in Europe) re-bored twice....and 1 crank grind.....
for anyone interested, unless the quality has change those heater plugs were always useless....
I looked after a fleet of narrow boats and our conversion was to weld up a large-ish lug on the inlet manifold then drill and tap to fit a Massey Ferguson tractor heater (diesel fuel) starter device....in fact any boat conversion I ever did the client never got the option, they got the mod anyway.....
my current engine I've owned for nearly 40 years......
this engine is fitted to a early 50's Morris J pick-up......incidentally I took 2 Los-Angeles and drove back via Texas.....
all u people must watch out, this crap they call fuel with the "bio fuel oil" mix eats seals, fuel lines, copper pipe and aluminum....on the old engines where they still have the old compound for seals I add a pint of engine oil for 5 galls of fuel.....bit like 2-stroke really....
anyone interested in old vans and motorcycles always happy to chat....
cheers, clogs
...
 
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