Problem with loose fuel injector / broken studs

What's on your mind? Anything generic goes here.

Problem with loose fuel injector / broken studs

Postby vt97john on Fri Dec 28, 2018 5:49 pm

I took a ride on my 2013 R29 a few days ago and she was running normally for a few minutes. Then something happened suddenly and there was unusual engine noise / engine rhythm and smoke started coming into the cabin. I shut it down. After getting towed back to the marina, I had a mechanic look at it and he found that the problem was that a fuel injector had broken loose (see detailed notes below). As anyone else had this occur? He said it's unusual and he can't imagine what would cause the cast iron clamp to break. He said he might contract a local Yanmar dealer to dig a little deeper. Any insight the tug nuts might have to offer would be great.

"Service call in local area, include 1st hour labor: Evaluate smoking and engine running issue.

Removed front and top covers from engine. Started engine and immediately shut down as source of smoke was obvious.

Discovered the #1 cylinder fuel injector loose, clamp block broken and laying on engine, 2 securing studs broken off. Also, #2 cylinder injector clamp block is broken, but still in place.

As a side note, 4 machine screws holding intake manifold to engine were visibly loose, tightened them up.

DO NOT RUN THIS ENGINE UNTIL THESE PROBLEMS ARES RESOLVED.

Left message for Karl's Marine Engines with details of issue. Will follow up with him to get this resolved. This may be after the new year.
"
___________________
John Mallonee
Port - Deale Maryland (Chesapeake Bay)
Home - Arlington Virginia
2013 Ranger Tug R29
vt97john
 
Posts: 52
Joined: Sat Sep 22, 2018 7:26 am
City: Arlington
State/Province: VA
Ranger/Cutwater Model: R-29 Classic
Vessel Name: TBD

Re: Problem with loose fuel injector / broken studs

Postby BradOwens on Fri Dec 28, 2018 5:59 pm

John,

I haven't had this issue, but I wonder if someone stepped on the engine cover while climbing into, or out of, the engine compartment. I have a "NO STEP" sticker on mine, but I still worry that someone may do it, as it is the most convenient way in or out.
Brad Owens

A boat is a hole in the water that you pour money into.
It's also a hole in the water that you get happiness out of!
BradOwens
 
Posts: 292
Joined: Fri Sep 25, 2015 7:32 pm
City: Bothell
State/Province: WA
Ranger/Cutwater Model: R-29 Classic
Vessel Name: Serendipity
MMSI Number: 367703440

Re: Problem with loose fuel injector / broken studs

Postby vt97john on Fri Dec 28, 2018 6:15 pm

I do indeed step on the engine cover when I enter the engine compartment. I assumed I was stepping on a solid block.
___________________
John Mallonee
Port - Deale Maryland (Chesapeake Bay)
Home - Arlington Virginia
2013 Ranger Tug R29
vt97john
 
Posts: 52
Joined: Sat Sep 22, 2018 7:26 am
City: Arlington
State/Province: VA
Ranger/Cutwater Model: R-29 Classic
Vessel Name: TBD

Re: Problem with loose fuel injector / broken studs

Postby fishheadbarandgrill on Sat Dec 29, 2018 6:07 am

BradOwens wrote:John,

I haven't had this issue, but I wonder if someone stepped on the engine cover while climbing into, or out of, the engine compartment. I have a "NO STEP" sticker on mine, but I still worry that someone may do it, as it is the most convenient way in or out.


I’m also new to a R29 Classic and thought the whole idea of the engine cover was to protect the top of the engine so you could step on it. Now If the bolts holding the cover came lose, then you could have a problem with the cover impacting the top of the engine?
Bob Menches
2011 R29
SEA SHANTY
Southport, NC
fishheadbarandgrill
 
Posts: 66
Joined: Sun Jul 15, 2018 8:29 pm
City: Southport
State/Province: NC
Ranger/Cutwater Model: R-29 Classic
Vessel Name: Sea Shanty

Re: Problem with loose fuel injector / broken studs

Postby knotflying on Sat Dec 29, 2018 8:02 am

Vibration could be the culprit. If things were not properly torqued down originally, over time vibration can do a lot of damage.
“What we call reality is merely an ILLUSION we create for learning and enjoyment….”
knotflying
 
Posts: 4218
Joined: Sun Jul 25, 2010 5:42 pm
City: Charlestown
State/Province: RI
Ranger/Cutwater Model: R-27
Non-Ranger Model: http://illusionsmikeandjess.blogspot.com/
Vessel Name: (2011) Illusions

Re: Problem with loose fuel injector / broken studs

Postby Brian B on Sat Dec 29, 2018 8:11 am

This is the first I have read on this site about injector clamps and studs breaking. Were the injectors ever removed? Perhaps they were not tightened to specs. On the Yanmar 4BY-2 there was an injector service bulletin some years ago on some of the engines.
Stepping on the covers is not a good idea, it will eventually damage the covers. Hard to believe that doing so could break injector clamps and studs.
I remember reading on here that one owner removed the covers completely so he could see what was going on under them.

Keep us posted on the fix and what they determine to be the cause of the failure.
Brian B
 
Posts: 786
Joined: Thu Apr 19, 2012 11:53 am
City: West Warwick
State/Province: RI
Ranger/Cutwater Model: R-25 SC
Vessel Name: GANSETT RANGER (2010) Yanmar 4BY2-150

Re: Problem with loose fuel injector / broken studs

Postby Brian B on Sat Dec 29, 2018 9:14 am

On page 6-12 of the service manual the injector nuts should be tightened to 71 inch lbs.
Brian B
 
Posts: 786
Joined: Thu Apr 19, 2012 11:53 am
City: West Warwick
State/Province: RI
Ranger/Cutwater Model: R-25 SC
Vessel Name: GANSETT RANGER (2010) Yanmar 4BY2-150

Re: Problem with loose fuel injector / broken studs

Postby GA-Midnight Cruise on Fri Jan 04, 2019 10:49 pm

Unusual. Usually when under torqued you will notice blow by that prompts you to confirm them with a torque wrench. But this is an unusual one. Sounds like it may have been over torqued and operating conditions was the catalyst? Were your injectors recently serviced or rebuilt?
GA-Midnight Cruise
 
Posts: 116
Joined: Sat Nov 03, 2012 9:18 pm
City: Alpharetta
State/Province: GA
Ranger/Cutwater Model: R-21
Non-Ranger Model: R21, Square Grouper: R21, Goliath: R21, Sweet Pea
Vessel Name: St. Brendan

Re: Problem with loose fuel injector / broken studs

Postby NorthernFocus on Sat Jan 05, 2019 11:44 am

Broken studs are almost always due to over torquing them combined with operating stresses/vibration. What is odd is the the studs and the bracket were broken. Typically once one or the other fails tension is relieved on the remaining fastener. Unless they all suffered a transient event such as cylinder overpressure(e.g. liquid injestion). At any rate I'd say the broken fasteners/bracket and loose ones on the manifold are not mere coincidence. Sounds suspiciously like the engine was either worked on in the past or experienced a transient event.

The only thing I'd rule out is the potential of having been damaged by stepping on it. Tubing, wiring, etc, are subject to damage from stepping on the engine but not mechanical fasteners. Not a good idea to step on the engine but it's not likely to cause this type of damage.
Dan

Never confuse confidence for competence.
NorthernFocus
 
Posts: 882
Joined: Sun Jun 29, 2014 9:02 am
City: Wasilla
State/Province: AK
Ranger/Cutwater Model: R-25 Classic
Vessel Name: Divine Focus


Return to Chat

Who is online

Users browsing this forum: No registered users and 11 guests