Need help Westerbeke 40 (Perkins 4.108)

[River Runner]

I love this forum, but this is my first post. I bought a 1963 Chris Craft Sail Yacht 35 as is. The engine wasn’t running, so I changed all the fuel filters and bleed the air out of the lines and she started. It really smoked, so I read the forum about all the causes for smoke and figured I had unburned fuel. I pulled the injectors and had them rebuilt, still smoked. So yesterday I decided to adjust the valve lash, when it was time for #3 it was missing a pushrod. No sign of it. What I need help with is where could it have gone and what should I do. I moved the boat from Alameda to Stockton last November, it didn’t burn any oil or didn’t make any unusual noises. If is possible that it is laying down in the oil sump, I don’t know if removing the pan is an option. I sent an email to the previous owner asking if it may have been removed by him, but have not received a response. Has this happened to anyone else?
Thanks-Rob

[sailormed]

Maybe it was never there? Engine assembled in a hurry or by an incompetent mecanic. Anyway it is an easy explanation for the smoke of the unburnt fuel. Install the rod and your engine is running smooth 😊

[River Runner]

Thanks, but the owner before the person I bought it from was a meticulous sailor a retired merchant marine. I don’t think that would have got past him. But who knows.

[skipperpete]

Remove the coverplate below the intake manifold, it probably is in there. Tight fit but.... maybe!

[skipperpete]

And it will most likely be a bent pushrod , perhaps from a stuck valve.

[River Runner]

Thanks Skipperpete!
That would be a good start to locate it. Can you think of anything I may need to remove to be able to get to the cover?

[drdoyle]

These engines (4-108) are not too bad for a small diesel. I've used them in the past for generators. They go about 12,000 hrs before an in frame hone and ring job (new piston connecting rod bearing/bushing) and head recon. They do have some weaknesses such as 50 hours oil changes for very dirty oil. Keep a spare Fresh water pump as the seals go every once in awhile. The biggest weak spot is the heat exchanger. The fuel pump lasts about 3500 hours and injectors a thousand hours. I did have a few cracked HP fuel lines at the nut seal mainly on #4. I prefer the "Bowman" heat exchanger units. I have moved on to the Isuzu 4LE engines for generators now and even then they are of last grreation technology - but really good.

[Svsumurun]

Originally Posted by River Runner

Thanks Skipperpete!
That would be a good start to locate it. Can you think of anything I may need to remove to be able to get to the cover?

Pretty sure the intake has to come off , it'd be aweful tight trying to get it out without it out of the way

[River Runner]

Thanks SVsumurun,
I think you’re right, I call the engine area the hole. The front of the engine has great access but either side you work by feel. This little engine is tough, if it ran this good on 3 cylinders, I can’t wait to try it with all 4!

[River Runner]

Originally Posted by drdoyle

These engines (4-108) are not too bad for a small diesel. I've used them in the past for generators. They go about 12,000 hrs before an in frame hone and ring job (new piston connecting rod bearing/bushing) and head recon. They do have some weaknesses such as 50 hours oil changes for very dirty oil. Keep a spare Fresh water pump as the seals go every once in awhile. The biggest weak spot is the heat exchanger. The fuel pump lasts about 3500 hours and injectors a thousand hours. I did have a few cracked HP fuel lines at the nut seal mainly on #4. I prefer the "Bowman" heat exchanger units. I have moved on to the Isuzu 4LE engines for generators now and even then they are of last grreation technology - but really good.

Yeah, I get parts easy and affordable, parts4engines has been great. The engine is old school like me. Our car has a Mercedes 6 cylinder diesel turbo in it everything is computerized, I open the hood look at it and take it to the dealer. Our Stockton Sailing Club has a great crane on the dock. When it’s time I’ll pull the engine, paint the bilge and replace old wiring. But not during Sailing weather!

[Svsumurun]

And you've already done the hard part on this engine , the fuel bleeding procedure on these is infamous ... my debacle last summer was the closest I ever came to walking away and giving up on anything mechanical in my life ...

But ... FYI .. I had also bleed mine numerous times before that time and never had an issue , so that floating westerbeke/Perkins air bubble might get you yet !

[River Runner]

Yes, after the injectors were rebuilt it was time to bleed those lines. You feel around for the 5/16” bleed screws, diesel gets on it the wrench then down to the bottom of the bilge it drops. Time after time. Can’t hardly wait till next time.

[River Runner]

Originally Posted by skipperpete

And it will most likely be a bent pushrod , perhaps from a stuck valve.

I got chills when I found an almost empty can of starting fluid in the hatch. With air in the lines he cranked it over so much he had to replace the starter motor. If he got crazy with the either, that’s what could have bent the rod. I hope I can find it.

[River Runner]

Thanks everyone for all your help. Looks like I’ll be removing the intake manifold and tappet cover and looking for the missing pushrod. I have a new pushrod ordered and hope it all goes well.
Thanks again!

[Scubaseas]

Maybe put a camera down the pushrod hoe before ripping it apart. That and a grabber works surprisingly well. An example https://www.amazon.com/Inspection-Fa...42732349&psc=1