Engine Clean-Up Complete

[Key2Cay]

We bought our boat in July and had a survey done of the boat as well as a separate survey done of the engine, a Cummins 6BT5.9-M 210hp. The engine survey found a strong engine in need of some TLC. The oil analysis raised no concerns from my engine surveyor who had over 45-years of experience servicing Cummins engines.

As a newbie to diesel engines, so I took a marine diesel class at my local community college. I met some wonderful people and learned a ton. It was the best $180 I could spend. I now have the knowledge and confidence to service and maintain my engine as we seek to start cruising next winter.

After about 160 hours of work, my engine is reassembled and running great.

Here are the things that I did: removed old raw water pump; installed a new raw water pump; drained all the coolant; rebuilt my original raw water pump (as a class project); removed and inspected exhaust manifold; installed new gaskets to exhaust manifold; removed and inspected turbocharger; installed new gasket to turbo; removed heat exchanger and cleaned throughout (soaked in vinegar for 24 hours) and stripped and re-painted it; removed all hoses and replaced with new hoses and double ABA clamps (where possible); removed and replaced oil line to turbocharger; removed engine wire harness and made a new one using Cummins standard wire colors; replaced starter with API step down design; replaced starter solenoid with mag switch starter solenoid; removed and replaced all senders and switches on the engine and transmission; removed injectors and had them inspected and serviced at a diesel service center in New Bern; removed and replaced transmission oil hosed to oil cooler; replaced transmission oil cooler; drained and replaced transmission oil; replaced belt tensioner; replaced belt; replaced thermostat with new 165 degree thermostat; added remote oil filter set up to make maintenance access easier; added a SMX EnviroVent system to capture crankcase venting; added a Reverso oil change system to engine and transmission; replaced wet exhaust hose from engine to lift muffler; added an exhaust temperature alarm switch to trigger if there is a temperature rise above normal operating conditions (i.e. from reduced raw water flow); added new group 31 start battery with cutoff switch in saloon and new 2/0 cables with an inline fuse; added new battery charger isolator; cleaned and cleaned and cleaned and then painted; added coolant overflow tank; added new coolant; replaced all fuel filters; blead the system; and adjusted valves.

I think the picture speaks for the engine. My confidence to do this is priceless.

You can also check out the video https://youtu.be/BNOVM3R0O6Y I made for my final class project last week - adjusted the valves and got her running.

[Sprig1]

That is a thing of beauty! Congratulations

[WillieC]

A clean engine is a happy engine. And you get to see where oil or anti-freeze is leaking, what is overheating, what is rubbing! I had a spot of rust show up between two injector lines in a tight rack. Ten years ago I never thought about rusting injector lines until I heard how much it would cost to replace them! Very nice work.

[Key2Cay]

Very nice work.

Thanks, Willie. I'm sure it will pay me back with my new understanding of the engine.

[DCatSea]

That's a Bristol engine room if ever I saw one. KUDOS! Now I have to clean mine up.