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MTU 16V4000 Overhaul - documented with pics

Discussion in 'Engines' started by Jorge Lang, Aug 1, 2018.

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  1. Jorge Lang, Aug 1, 2018
    #1
    Jorge Lang

    Jorge Lang Senior Member

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    I am in the process of documenting the overhaul of a MTU 16V4000. This will be posted once the engine has been assembled and back on the vessel. Currently the engine has been stripped down to the block to gain access for the removal of the defective crankshaft. The engine looks much different in pieces than it does on a vessel. I would like to invite YachtForums members to stop by and have a look at what this beast looks like on the inside and the 21 pallets of parts removed from the block. If you are in the Fort Lauderdale area and would like to stop by, send me a PM so we can arrange for the visit.
  2. Capt Ralph, Aug 1, 2018
    #2
    Capt Ralph

    Capt Ralph Senior Member

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    This is a real cool invite. Thank you.
    I look forward to your completed post.
    Can you comment now on the crank? Factory or induce defect?
    That has to be a monster of a crank and engine.

    Look forward to pics of the R&R also. That had to be real fun....
  3. Jorge Lang, Aug 3, 2018
    #3
    Jorge Lang

    Jorge Lang Senior Member

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    Teaser photo, let me know if you want to stop by next week to see the block, and nothing but the block.

    Attached Files:

  4. Capt Ralph, Aug 3, 2018
    #4
    Capt Ralph

    Capt Ralph Senior Member

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    looks like more than a crank problem. #6 & 7L look bad.
  5. Jorge Lang, Aug 3, 2018
    #5
    Jorge Lang

    Jorge Lang Senior Member

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    Ralph, what's wrong with the picture of the crankshaft?

    Attached Files:

  6. Capt Ralph, Aug 3, 2018
    #6
    Capt Ralph

    Capt Ralph Senior Member

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    That's not good. Spun & ground rod bearings. Counter weight may have been beating on something also.
    Rods are toast also I'm sure.
    Great reef material though..
  7. MBevins, Aug 3, 2018
    #7
    MBevins

    MBevins Senior Member

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    Did you see the guy standing at the end, that's perspective. This thing is huge.
  8. olderboater, Aug 3, 2018
    #8
    olderboater

    olderboater Senior Member

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    What is the anticipated time frame from the moment work started to remove it from the boat until the boat will be ready for use again?
  9. K1W1, Aug 4, 2018
    #9
    K1W1

    K1W1 Senior Member

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    That's an older low output 16v4000 which is normally a very reliable unit. How many hours had it done before the failure and was there any external problem or was it just plain worn out?
  10. Capt J, Aug 4, 2018
    #10
    Capt J

    Capt J Senior Member

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    This and the 2nd bore from the furthest away looks like the liner had a huge issue from the discoloration......
  11. Capt Ralph, Aug 4, 2018
    #11
    Capt Ralph

    Capt Ralph Senior Member

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    I thought the #6 & 7L looked bad. George did not comment.
  12. Jorge Lang, Aug 6, 2018
    #12
    Jorge Lang

    Jorge Lang Senior Member

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    It is most likely material failure on the liners. The engine has 8000 hours and the last service on it is unknown. We will restore it to its old glory. The engine block is now stripped and today we begin restoring the cylinder walls to the first repair station. It's not too late to stop by and see this work, let me know if you are interested.

    Attached Files:

  13. Capt J, Aug 6, 2018
    #13
    Capt J

    Capt J Senior Member

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    I’d say it had a good run with getting 8,000 hours. What did it come out of?
  14. Jorge Lang, Aug 16, 2018
    #14
    Jorge Lang

    Jorge Lang Senior Member

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    After machining, the block is now ready for some serious work. The new crankshaft has arrived and we will be working 12 hour shifts to get this guy back together again. Capt J, this came off a ferry. As mentioned before, you are welcome to stop by and see the progress in person, just send me a pm to schedule the visit.

    Attached Files:

  15. Jorge Lang, Aug 27, 2018
    #15
    Jorge Lang

    Jorge Lang Senior Member

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    Sorry I haven't been posting the pics, I was in Puerto Rico for a few days. So here's the update. Crankshaft has been installed and liners are in. Everything has been torqued down and we will begin the pistons soon.


    New cylinder liners

    LINERS YF.JPG


    LINERS COMPLETE YF.JPG



    Here's the shiny new crankshaft
    CRANKSHAFT ASSY YF.JPG

    CRANKSHAFT INSTALL YF.JPG
  16. Jorge Lang, Sep 5, 2018
    #16
    Jorge Lang

    Jorge Lang Senior Member

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    14 of 16 Cylinder Heads are now installed.
    CH 1 YF.JPG


    Check out the engine stand.
    CH 2 YF.JPG
  17. Capt Ralph, Sep 5, 2018
    #17
    Capt Ralph

    Capt Ralph Senior Member

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    I like the engine stands.
    Tell me about the main caps and studs.
    Was there a crank bore surveyed? Were the cap studs new?
    How about those rods for the damaged throws, New rods there or all?
    Big smile, how did the #3 left & #3 right get left out till last?
    Tell me about the cam shaft, New? With that much bearing material flying about I had to ask.
    Don't mean to be an arm chair quizzer, I've never built anything this large and wander if these details are an option or concern on these large blocks?

    In my old days building gas engines and small diesels (cave man times), I remember de-buring and pinning every item. Mirror polishing every side of thrust areas.
    Shimming up thrust washers to center all rods. CCing heads.
    My best friend Plasti Gauge, 3 points on every half bearing. Best gal Molly lube on every lobe.
    Frank Schooler (long passed) turned every shaft and balanced all that moved.

    Are any of these thought involved on these ole beast? Or, Just as the factory ordered?
  18. Jorge Lang, Sep 6, 2018
    #18
    Jorge Lang

    Jorge Lang Senior Member

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    Capt. Ralph,

    As I'm not an engine expert (yet) I needed to check with my guys here at the shop so here are your answers;

    Yes, the main bearing bore was surveyed.
    Both #3's have not been installed as we are waiting for new connecting rods to arrive.
    The Cam shaft is new.
    The cap studs were not replaced.

    As mentioned previously, if anyone would like to stop by and see the progress, just send me a PM.
  19. Capt Ralph, Sep 6, 2018
    #19
    Capt Ralph

    Capt Ralph Senior Member

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    Ah, So just the two spun rods will be new.
  20. Jorge Lang, Sep 18, 2018
    #20
    Jorge Lang

    Jorge Lang Senior Member

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    Now that I'm back from the Newport show, here's an update. Connecting rods came in and pistons and cylinder heads are installed. Also the fuel rails are also now in.

    CYLINDER HEADS COMPLETE YF.JPG


    We now have started with the rocker arms. The cylinder head covers are being used to protect little issues like "stuff" falling into the engine block.

    ROCKER ARMS BEGIN.JPG
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