Arrived early at the boat. Mark and I finished up making 4 battery cables and put the batteries on charge.
Ashok went upside down in the bilge to install the wet muffler and also reassembled the heat exchanger and serviced the cooling
Installed the alternator and reconnected all of the electrical
. Then the spark check. OK, no sparks but...
The distribution panel lit up but the engine panel did not. Everything on the house worked. Lights, vhf
, instruments etc. etc.
Darn - Electrical troubleshooting is not hard but it is very methodical and time consuming. And we made a critical error right at the start - as one always does. Got the multimeter out.
There was a ground wire broken on the alternator. We didn't have a new lug but we flashed the alternator case to ground and convinced ourselves the alternator was grounding through the case - bad call...
Double and triple checked the battery wiring. All good.
There is a "home made" wire loom with one leg attached to the alternator positive and the other leg attached to the engine ground. We manually traced it as far as possible and then guessed it was the panel power. Later it turned out to have nothing to do with the engine but wiring can lead you on many goose chases.
Early on I said it indicated like a bad engine panel ground but we continued.
The engine panel harness attaches to a box on the port aft of the engine right above the starter. There was a fuse pack on it. Removed and checked the fuses
Decided to remove the engine panel. Confirmed power was getting to the panel and that the master switch was working. Grounding the voltmeter on the engine block - removed that "home made" loom and made no difference. That loom has nothing to do with panel power. The power comes from the starter secondary and into the engine harness.
Finding out what that harness does is a job for another day...
So we check attached the the "failed" ground wire and bing - the panel lights up. Damn, it was a ground problem and the ground lug on the alternator is isolated from the case (of course it is) and there is no way to ground the alternator field and engine panel unless the ground wire is attached.
Rob took the opportunity to remove all the plugs on the back of the panel and clean them, lubricate and reinstall.
Reassemble the alternator for the 4th time or so. Secure the engine panel and all is good. About a 2 hour diversion.
Wanted to take pics but after charging
all night the battery was dead - another electrical device trying to make me crazy.
So the last job - Reinstall all the engine fuel system stuff. New gaskets and parts all round. I like new parts.
Install a new fuel filter.
Bleed to the fuel filter, bleed to the injector pump
. All seems good.
Crank the engine and get positive pressure from both pump outlets. Install the new injectors. Install the injector lines. Crank the engine and bleed out the injector lines.
The moment of truth!