Engine out and disassembled

After almost two months since hearing a problem in my new Westerbeke engine the engine has been removed and disassembled in the diesel shop. It turns out it was NOT what I expected. It was not a bent rod or a bad rod bearing as four mechanics had thought.  The noise was a result of the 4th cylinder only occasionally firing due to serious corrosion. The 3rd cylinder was not much better. Also, the entire interior of the engine was full of carbon and gunk due to incomplete combustion caused by excessive backpressue.  The damage is the result of the cumulative process of water intrusion through the wet exhaust sytem since the engine was installed.

The engine is basically destroyed and beyond economical repair.

The engine was laid out at the diesel shop in Chula Vista like something from "CSI Diesel". All the parts laid out for inspection, analysis, and photographing. What an ugly mess. The poor combustion and the heavy salt water backflow had left it black and gooey and rusted all through the interior.

It could be worse. I am just thankful that I detected the strange sounds from the engine the week before I was scheduled to sail with my crew to Mexico in the Baja Haha. I am thankful that I made the decision not to leave port until the problem was resolved. Had I not taken these actions then I would probably be sitting in Mexico with an engine that is totally destroyed, an improperly designed exhaust system, and far from people who could help me resolve this problem.

Here are some pictures of the engine removal. It was must easier than I expected. Three men had the engine out and on the dock in about 2 hours. I was really surprised. However they were very experienced professionals and knew what they were doing. That always helps.

Here is the engine being disconnected from fuel, water, cooling, shaft, etc. and prepared for lifting.

Lifting the engine out of the engine compartment, which is below the cockpit sole.

The engine resting on the cockpit sole and ready to be manhandled aft to beneath the companionway.

The engine comes up through the companionway.  The end of the boom is being used as a lifting point for the hoist.

The engine, without the transmission, is swung out over the pier using the main boom as a crane.

The engine is apart and layed out in the diesel shop like something from "CSI Diesel Engine".  It is apparent that there was serious water intrusion form the wet exhaust system and also incomplete combustion due to excessive backpressure.  The engine is ready for the boatyard to inspect.  Now I wait and see if the boatyard will accept responsibility for their work.  I trust they will.