Current Position: 33 01.608’S 17 597.628’’E; Timezone: UTC+2; SOG:0; COG: N/A; TWS: 10; TWD: 006; Current Speed: 0.7 kt; Current Direction: 199; Distance to Waypoint (Saldanha): Moored; Total Miles Sailed: 16600 nm; Engine Hours: 409; Estimate Fuel: 54+11+50;
Comments: I woke up in the middle of the night and figured out what went wrong with the engine. When I overfilled the main tank it pushed unfiltered fuel into the day tank via the vent line. I need to drain the day tank. The problem is I am at capacity and don’t have anyplace to put the fuel. I ran the engine for 408-393=15h. I probably used 8-9 gal of fuel. However, the main tank was overfilled by maybe 3-5 gal, so I need to find capacity for perhaps 10 gal of fuel to drain the tank. The only way I can think of doing that is to give away the fuel in two Jerry cans. The good news is the injectors may be fine. If I can clean up the fuel, I will test the engine before pulling the injectors. After soaking the old injector nozzles in PB Blaster overnight, I was able to separate one of the pintles from its nozzle. I returned the others to the bath to soak. This means I gave at least one backup if I end up pulling the injectors from the engine and find one is fouled and cannot be cleaned. After thinking about it a bit, I realize I had already anticipated the problem of emptying the day tank into the main tank. I just had to turn two ball valves. There should be just enough room in the main tank to do it. While the fuel was pumping, I decided I needed to look at the injectors. Just as I did in Dawin, I broke the fuel return manifold while getting the injectors out. I bought a spare, but only one. When I install it I will not have a backup. It was good that I pulled them as they were fouled. More significantly, the second from the front came out with its heat shield because I had accidentally used two copper washers in Darwin. This means that cylinder was probably not firing as well. I was able to get the heat shield off without damaging it. I had an important decision to make. Should I two to take the injectors apart and clean them while risking damaging one. It seemed unlikely I would be able to get the pintles out, and the rest of the inside of the injectors were probably fine. I decided to soak the ends of the injectors for half a day and reinstall them. I dare not risk pulling them out again without getting another fuel return manifold. I changed the oil, but remarkably I did not have a spare oil filter. That is very surprising because I thought I had plenty of them. I was so sure I had them, I didn’t check before I started changing the oil. I thought perhaps I put the “extra” spare air and oil filters somewhere else, but I do not think so. I have decided I cannot go without these filters, so I am taking a Uber to a local AutoZone. Before going, I checked the day tank and it had still not been emptied after several hours. I changed the Racor fuel filter and the back pressure dropped significantly. I can hear the fuel dropping into the main tank. I visited two auto parts stores, but neither had either filter. I can back, reassembled the engine, and pumped fresh fuel into the day tank. The engine runs smoothly but it still smokes. I tried removing the air filter to make sure enough air was being delivered, but that did not help. I put some additive in the day tank that is supposed to clean injectorsand ran it for an hour, but that did not help. My choices are to pull the injectors again or just leave. I can try to take the injectors apart, but given my experience with the other set, that probably is not going to happen, so I would have to find a place that can service them locally. That probably means moving the boat. Also, I am certain I would have to check out again. If I pull the injectors again, I risk break the return line. It could take weeks to get a replacement. I am going to sleep on it, but I am inclined to leave. If I do, it means only using the engine when absolutely necessary (in and out of ports, etc.). Just fire it up every few days to keep it lubricated. I found the name of a person in a nearby town who cleans and calibrates diesel injectors. I contacted him and tomorrow is the last day his shop is open until they close for the holidays. He said he could service the injectors tomorrow. I managed to remove the injectors without damaging the fuel return manifold. I spoke with the marina office about not being able to leave tomorrow. They said don’t worry about it … even if I cannot leave until Monday it will be fine. I am Going to pump the fuel back out of the day tank, remove the fuel drain line, and empty the last little bit that the pickup tube misses. I will also replace the fuel filter (thereby removing the last of the fuel in the engine.
Comments: I woke up in the middle of the night and figured out what went wrong with the engine. When I overfilled the main tank it pushed unfiltered fuel into the day tank via the vent line. I need to drain the day tank. The problem is I am at capacity and don’t have anyplace to put the fuel. I ran the engine for 408-393=15h. I probably used 8-9 gal of fuel. However, the main tank was overfilled by maybe 3-5 gal, so I need to find capacity for perhaps 10 gal of fuel to drain the tank. The only way I can think of doing that is to give away the fuel in two Jerry cans. The good news is the injectors may be fine. If I can clean up the fuel, I will test the engine before pulling the injectors. After soaking the old injector nozzles in PB Blaster overnight, I was able to separate one of the pintles from its nozzle. I returned the others to the bath to soak. This means I gave at least one backup if I end up pulling the injectors from the engine and find one is fouled and cannot be cleaned. After thinking about it a bit, I realize I had already anticipated the problem of emptying the day tank into the main tank. I just had to turn two ball valves. There should be just enough room in the main tank to do it. While the fuel was pumping, I decided I needed to look at the injectors. Just as I did in Dawin, I broke the fuel return manifold while getting the injectors out. I bought a spare, but only one. When I install it I will not have a backup. It was good that I pulled them as they were fouled. More significantly, the second from the front came out with its heat shield because I had accidentally used two copper washers in Darwin. This means that cylinder was probably not firing as well. I was able to get the heat shield off without damaging it. I had an important decision to make. Should I two to take the injectors apart and clean them while risking damaging one. It seemed unlikely I would be able to get the pintles out, and the rest of the inside of the injectors were probably fine. I decided to soak the ends of the injectors for half a day and reinstall them. I dare not risk pulling them out again without getting another fuel return manifold. I changed the oil, but remarkably I did not have a spare oil filter. That is very surprising because I thought I had plenty of them. I was so sure I had them, I didn’t check before I started changing the oil. I thought perhaps I put the “extra” spare air and oil filters somewhere else, but I do not think so. I have decided I cannot go without these filters, so I am taking a Uber to a local AutoZone. Before going, I checked the day tank and it had still not been emptied after several hours. I changed the Racor fuel filter and the back pressure dropped significantly. I can hear the fuel dropping into the main tank. I visited two auto parts stores, but neither had either filter. I can back, reassembled the engine, and pumped fresh fuel into the day tank. The engine runs smoothly but it still smokes. I tried removing the air filter to make sure enough air was being delivered, but that did not help. I put some additive in the day tank that is supposed to clean injectorsand ran it for an hour, but that did not help. My choices are to pull the injectors again or just leave. I can try to take the injectors apart, but given my experience with the other set, that probably is not going to happen, so I would have to find a place that can service them locally. That probably means moving the boat. Also, I am certain I would have to check out again. If I pull the injectors again, I risk break the return line. It could take weeks to get a replacement. I am going to sleep on it, but I am inclined to leave. If I do, it means only using the engine when absolutely necessary (in and out of ports, etc.). Just fire it up every few days to keep it lubricated. I found the name of a person in a nearby town who cleans and calibrates diesel injectors. I contacted him and tomorrow is the last day his shop is open until they close for the holidays. He said he could service the injectors tomorrow. I managed to remove the injectors without damaging the fuel return manifold. I spoke with the marina office about not being able to leave tomorrow. They said don’t worry about it … even if I cannot leave until Monday it will be fine. I am Going to pump the fuel back out of the day tank, remove the fuel drain line, and empty the last little bit that the pickup tube misses. I will also replace the fuel filter (thereby removing the last of the fuel in the engine.