Man D2848LE403 800 hp 5,000 hour cost?

Assuming they need no kits or parts other than routine... $60,000.

Estimates to bring our 900-hp versions (common rail version of 403s) back into MAN service schedule (M1-M6, A1, A2) was ~$24K.

Excluded potential corrosion damage to expansion tanks, tube bundles, etc., excluded unforeseen issues, etc etc etc. Tank, $1295; thread repair, $65; tube bundle, $1150, solder, press check, labor, per each, etc.

Dunno how/if the 406 service schedule compares with the 403 schedule.

-Chris

Ah. I had a brain phart. LE 423 is correct, thanks for the heads-up.

I'd suspect 403 rehab to be lower than ours, but don't really know enough about the differences -- other than the electronics -- to justify my suspicion.

The estimate I mentioned was a pre-contract "what if?" exercise. Bubba couldn't produce any (ANY!) engine service records... so I postulated it must not have happened. Had the nearest (to the boat) MAN people take a stab at what it would cost to bring the engines back into schedule compliance.

Actual (eventual) cost was about twice the estimate, since during survey/sea trial the MAN guys also discovered the MMDS boards needed repair, the displays needed repair, B-bank exhaust risers needed replacement (fabrication), one of the expansion tanks needed repair... plus all the little stuff... and it eventually took about 150 labor hours. (Much of this extra cost was addressed in subsequent contract negotiations.)

-Chris

Not clear from my records what the symptoms really were. Survey wording was:

21. Port/Stbd displays; Port reverts to metric, Stbd has lines in the screen; recommend refurbishing both displays.
22. Port/Stbd MMDS boards engine hours are erratic; recommend repairing both boards.​

Not a surprise. Engines at the time were at ~1570 hours. I'd read prior to all this that MMDS boards and display would likely be an issue, either immediately or sometime "soon." Sure enough.

-Chris

I have the 403's and did the same service as ranger including rebuilding the water pumps, testing and replacing (about half) the injectors, plus the oil cooler gaskets replacement. Travel and shipping between Knoxville and Wilmington , DE = $27.5k in 2019

Just expect more than you think to bring any overdue MAN or any marine diesel back to good condition. We had our 2848-423 (CR900's) serviced back in June was 25k but during the valve lash found a worn valve that required a new head which was another 10k with labor. Also found a few other issues. There will always be something to replace on old engines. To my knowledge most MAN parts are available but can be hard to find often need to be shipped from Germany.

Ben, do you have any pictures of the worn valve ? thanks.

Mod Edit: images reduced to fit our format. Please read the rules on image sizes.

The first photo is the head with the circled exhaust valve that was measuring very high during the valve lashing. The second is the worn valve. The third is a normal valve. Im fairly certain previous owners skimped on maintenance.

So our mechanic recommended pulling all the heads and sending them to TX for inspection as that is the only way to put eyes on the valves and seats. That's a big job. I think we plan to keep the boat long term it's the best thing to do.