First drive after Volvo Penta renovation

It was time to finalize the installation of the engine so that we could test it after our Volvo Penta renovation. We had lifted it to the correct position and we needed to connect the gearbox to the engine and the propeller shaft and connect diesel, sea water, cooling system to the boiler and some electricity to the engine before we could do a test start inside the boat.

First up was to assemble the gearbox and then connect it to the shaft. The gearbox need to be inserted precisely to its correct position and we used our rig (that we used when lifting the engine into position) to get the gearbox correctly into position. After that we could connect the shaft.

The gearbox connected with the shaft.
Another picture of the connection to the shaft.

Then we connected the diesel, sea water and cooling system so that we could do a test start inside the boat. Here’s a video from the first test start:

Then we decided to take the engine out for a test drive. First we just drove around in the marina. If the engine would break then we would at least wouldn’t be out in the sea. We drove around inside the marina for a while and the engine behaved really good. Before doing our renovation the engine had trouble running on idle and when put it in reverse it died. Now it was no problem running on idle or to put it in the reverse! 🙂 But everything wasn’t smoothly. We had an oil leak in the gearbox and a sea water leak in the oil cooler. We will need to do further investigations of them.

Here’s a little video from our first drive inside the marina:

After driving around in the marina for about half an hour we drove to the islands of Fjäderholmarna and back to run the engine with some more speed. We drove around 3.5 knots, we don’t want to run the engine to hard in the beginning before all parts have run in together.

Another major improvement is the amount of smoke from the exhaust…

Smoke from the exhaust
A picture of how much smoke it was before we lifted the engine out from the boat. This was after we had ran the engine a couple of times, first time we started the engine it was even more smoke.
And this is how much smoke it is right now, almost nothing! 🙂

The reason we had that much smoke before was that the engine had bad compression and all the diesel didn’t incinerate properly.

Now it is time for some before and after pictures!

The engine and generator before we lifted them out of the boat.
After our renovation and cleaning the bilge.
Before lifting the engine and the generator out from the boat seen from the stern.
Seen from the stern after the renovation.
A picture of the generator, engine and the battery box. Next up will be to get all the electricity and all cables in order. It is quite a mess right now and we need to go through it.

Now the engine is classified as done (except for some small leakages). Our future renovation plans will be to:

  • Go over the basic electrical functions
  • Do some cleaning
  • Continue with the plastic repair in the cockpit
  • Go over the plastic on deck
  • Go through the rig

Installing our Volvo Penta engine

It was finally time to lift our Volvo Penta engine to its correct position in the boat and start the installation, after an entire winter of doing a full renovation of the engine (read all our blog posts about the renovation HERE). But before starting the installation we had to fix a small diesel leakage in the connection between our two fuel tanks. We noticed the leakage when lifting the engine into the boat but didn’t have the time to fix it immediately.

A not so nice surprise, finding diesel at the bottom of the bilge. Good thing that the bilge pump wasn’t connected and all this would have gone into the water. Now we could throw it into an environmental station instead.

So the first thing we needed to do was to fix the connection. We had a hard time get the connections in the correct position last time, since it is not very much room in the bilge and that is probably the reason for the leakage. We changed the connection and hopefully we won’t have any more leakages here.

Fixing the leaking connection between the fuel tanks.

As mentioned earlier, we had noticed a mysterious hatch. At first we wanted to open it to see what is inside it. But when we tried to open it we almost broke the plastic in the bilge so we decided to not open it and re-sealed it.

Sealing the mysterious hatch.

Then it was time to lift the generator into its position.

Lifting the generator into its position.
The generator in position.
The generator in position, seen from the cabin on starboard side. It is located under the bed in this cabin. The end of the bed can be removed so it is pretty easy to do maintenance on the generator if needed.

And finally it was time for the engine. First up was to get the external oil sump into its position.

External oil sump in position.

We used the same rig we built when lifting the engine out from the boat. It is made out of wood and we secured it towards the interior in the boat to get it really stable.

Time to get the engine into its position using our beloved chain hoist.
First we lifted it just enough to loosen it from the engine rig it is standing on right now.
Removing the engine brackets from the rig.
Then we moved it step by step, using the chain hoist and a strap to get it above its final position.
It was a precision task to get all of the engine brackets in the correct position. We sent the engine up and down for a while to get everything in position.
Finally in position!

Before it is time to try to start the engine we need to connect the gearbox to the engine and the shaft. We also need to connect the diesel, sea water, cooling system to the boiler and some electricity before we do our first test start inside the boat.

Generator renovation

In parallel of working with the engine, we also renovated the generator for our sailboat. The generator we have is a Zeise Liliput Multi Power. Our main focus during the winter was the engine and we just wanted to do what was necessary with the generator.

The generator right after we had lifted it out from the boat.

As everything else on the boat, the generator had been abandoned for ten years. We suspected from the start that the heat exchanger would be quite dirty, so we removed the heat exchanger to clean it.

Removing the heat exchanger.
Cleaning the heat exchanger. Can you see the dirty water?
Re-mounted the heat exchanger again and started the generator for the first time.

There were no problems running the generator, so there is not much that we need to do. But what we will do is:

  • Changing the fuel hoses
  • Changing the driving belts
  • Paint the covers for the generator
  • Change oil and coolant
Starting to remove the generator so that we could change the driving belt.
Generator removed.
One of the steel screws that held the generator had corroded badly into the aluminum of the generator. It was really hard to get rid of it. We tried with heat and a pipe wrench.
The evil screw finally removed.
Emptying the old oil, which, as you can see is very dirty.
Painting the covers for the generator.
One of the covers for the generator before cleaning and painting.
The cover after painting.
The generator after painting the bottom cover and cleaned it a bit.
After painting and cleaning on the other side.
Adding the cover.
The generator inside its cover.
The generator and the engine 🙂

We are still waiting for the ice to melt in the marina were we have the boat, but we hope that we will be able to lift the engine back in to the boat next weekend. To see all our posts about renovation, see the category Renovation, and for the posts about the engine, see category Engine.



Lift the engine out of the boat

October 2018

We had decided to lift the engine out of the boat, so that we could do a full service of the engine during the winter months. Our engine is a Volvo Penta MD19 with a weight of approximately 270 kg (595 lbs) so it would not be an easy task.

The first thing we did was to remove the gear box, before starting to lift the engine. This was necessary to make it possible to lift the engine out from its position. The gear box weighs approximately 30 kg (66 lbs), so the engine also weighed a little less, not much, but every kg counts.

We built a rig made of wood, with the rig and a chain hoist we were able to lift the engine out from the bilge. The chain hoist was very helpful, since we didn’t need to use our own muscles to lift the engine. Otherwise it wouldn’t be possible with just the two of us, and it would probably cause some pain in the back for those involved lifting. Now we could do the work ourselves, the whole process was very controlled and no back pain afterwards!

scaffolding with chain hoist to lift the engine out from the bilge
Our rig we used to lift the engine out from the bilge in the boat. We used a chain hoist, which was very helpful.
Starting to lift the engine.
Almost there!
Finally up on the flooring.
It was very dirty under the engine. If we wouldn’t have removed the engine, it would have been very hard to do a proper cleaning of the bilge. Now we can go through the bilge during the winter, clean it and take a look at all the hoses and electronics.
We also removed the generator. While we work on the engine we will try to start the generator and, if necessary, do some service to it.
Our next step was to lift the engine out from the boat. We used a derrick, it made the process controlled and no need for brute force.
The engine removed from the boat.
The generator on its way out from the boat.
Since the engine is heavy we built a rig to lift it into the car. The hardest past, we noticed, was to get the engine into the car. The engine is high, and together with the rig and chain hoist, it was higher than the car.
We managed to get the engine inside the car eventually, by using a little force from ourselves.
The engine in the garage, ready for some service 🙂
And the generator as well.

The next thing we will do is starting to remove all the parts of the engine. You can follow our service of the engine under the category Engine. All other renovation we do to our sailboat Anne-Mon can be found under the category Renovation.