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Old 12-09-2011, 01:10 PM   #21
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RE: 3208 n.a. coolant leak

I bought the used tube bundle. After talking to the tec support guy for NC machine. (The Cat dealer in Alaska.)* What he told me was that the guy in Seattle was a long time guy and if he said it looked good*it probably was.**** No written guarantee but chances are good it is a good unit.

I am hoping that a properly functioning heat exchange unit will fix my overheating issues.

We shall see.

*I plan on taping the installation project for a youtube clip just in case someone else has to do this job. I wish someone had done it before because I am not a mechanic. it should be fun as I am sure I will screw something up and have to repair my mistake. Wish me luck. The part will be in on Monday so next weekend will be the big show.

SD
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Old 12-10-2011, 07:13 AM   #22
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RE: 3208 n.a. coolant leak

Quote:
skipperdude wrote:


I bought the used tube bundle. After talking to the tec support guy for NC machine. (The Cat dealer in Alaska.)* What he told me was that the guy in Seattle was a long time guy and if he said it looked good*it probably was.**** No written guarantee but chances are good it is a good unit.

I am hoping that a properly functioning heat exchange unit will fix my overheating issues.

We shall see.

*I plan on taping the installation project for a youtube clip just in case someone else has to do this job. I wish someone had done it before because I am not a mechanic. it should be fun as I am sure I will screw something up and have to repair my mistake. Wish me luck. The part will be in on Monday so next weekend will be the big show.

SD
That's a great idea. Keep us posted!
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Old 12-23-2011, 08:59 AM   #23
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3208 n.a. coolant leak

After considerable research I have come to the conclusion That I need to replace the Water temperature regulators.

As I see it. I need to remove the expansion tank and heat exchanger.

Has anyone done this job?

*It sure looks like a lot of work. Mostly because of the available space to remove the darn heat exchanger.*

SD


-- Edited by skipperdude on Friday 23rd of December 2011 10:00:08 AM
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Old 12-24-2011, 05:30 AM   #24
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RE: 3208 n.a. coolant leak

Yes...pulled my two when I had the exchangers boiled mon my last boat.* They are HEAVY to boot so be carefull with the fingers on the last bolts!

Yeah...room is always the challenge but what boat has everything within easy reach of 2 hands and the proper tools?
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Old 12-26-2011, 10:16 AM   #25
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RE: 3208 n.a. coolant leak

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Yes...pulled my two when I had the exchangers boiled mon my last boat.*
*Did you pull the end caps and tube bundle first?

There is a lot of weight there the end caps alone must weight 20 lbs.

SD
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Old 01-23-2012, 01:29 PM   #26
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RE: 3208 n.a. coolant leak

I think I have found my coolant leak. After all the work and expense of rebuilding the heat exchanger system and a new water pump.

I* was ready to add coolant.

Did so and guess what?

A*leak.**This time I traced it down to the Water sleeves.

plastic tubes with O rings that fit at the end of the heads. going from the timing gear cover to the heads.

So the only way to replace them is to pull both heads.

A lot of work they weigh 120 lbs each. The injectors need to be removed also.

This is snow balling because if I am going to pull the heads I am going to rebuild the injectors or at least have them looked at.

OH man.

SD
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Old 01-23-2012, 06:41 PM   #27
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RE: 3208 n.a. coolant leak

oh MAN, thats some undertaking you have going there..

but look at it this way, with rebuild injectors and fresh heat exchangers, you are gonna have a well performing engine after.
i would love to get my injectors rebuild, but its costly unless you do DIY..
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Old 01-24-2012, 03:46 PM   #28
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RE: 3208 n.a. coolant leak

While you're in there may as well do a valve job! snowBALLS!!!!!!
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Old 01-25-2012, 08:10 AM   #29
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RE: 3208 n.a. coolant leak

Quote:
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While you're in there may as well do a valve job! snowBALLS!!!!!!
*Now cut that out!!!

SD
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Old 01-25-2012, 07:44 PM   #30
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RE: 3208 n.a. coolant leak

Have you tried a pressure test on the system? You know, the tool with the pump & little cap that attch to the coolant fill cap. You pressurize the system, watch the gauge for pressure retention/loss and look & listen for leaks. I was amazed how many of my clamps were oozing AF. Thing was, the heat from the engine running kept those leaks from showing up in the bilge. Was a big help. I do that on a routine basis now. Tool can be had on ebay, etc
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Old 01-26-2012, 06:20 AM   #31
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RE: 3208 n.a. coolant leak

I can only reach max RPM 2800 in nutral. Max RPM is about 2500. underway blows black smoke at WOT.

Now that you have some of the coolant leaks fixed its time to cure the overloading.

CATs are not particularly robust , so this becomes a priority.

*

IF reproping is not in the budget , allong with an injector check, at least an EGT will keep the damage down.

*

DO SOMETHING , or simply run 500RPM below wherever the black smoke begins.
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Old 01-26-2012, 09:37 AM   #32
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RE: 3208 n.a. coolant leak

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Have you tried a pressure test on the system?
*Yup. Did that looking for the leak. Didn't show any drop in pressure.

Me thinks once the coolant was removed the o rings on the water sleeve dried out and caused it to leak ?? Could this be??

Regardless I know it leaks there now.

This weekend I begin tearing down the engine I.E. removing the heads.

I've talked to a lot of people on what I need to do. Sounds like nuts and bolts and a bit of grunting 120 lb head.

I found a place that will test all 8 injectors for $25.00. since thay have to come out to pull the head may as well. I have a knock somewhere I think it may be an injector.

SD
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Old 01-26-2012, 09:40 AM   #33
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RE: 3208 n.a. coolant leak

Quote:
FF wrote:
I can only reach max RPM 2800 in nutral. Max RPM is about 2500. underway blows black smoke at WOT.

Now that you have some of the coolant leaks fixed its time to cure the overloading.

CATs are not particularly robust , so this becomes a priority.

*

IF reproping is not in the budget , allong with an injector check, at least an EGT will keep the damage down.

*

DO SOMETHING , or simply run 500RPM below wherever the black smoke begins.
*Thanks. Perhaps all of the above
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Old 01-26-2012, 10:53 AM   #34
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3208 n.a. coolant leak

As I said befor I've talked to a few people on removing the heads and injectors.

Anyone on the forum ever done this job before?

Any tips?

The little bugger I have to replace is seen between the red wire and the bleed tube hanging down at the end of the head,

*

SD



-- Edited by skipperdude on Thursday 26th of January 2012 12:03:56 PM



-- Edited by skipperdude on Thursday 26th of January 2012 12:06:52 PM


-- Edited by skipperdude on Thursday 26th of January 2012 12:09:10 PM
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Old 01-27-2012, 07:27 AM   #35
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3208 n.a. coolant leak

Any tips?

Think CAR , with just a bit heavier parts , but same skill set.

Most injector places will test your injectors for almost nothing ($5-$10 each), a full rebuild of your injectors is about $65 here in FL.

Sometimes during the rebuild you cam get "More" .

Better economy , more HP , less smoke , talk to the rebuilder.

*

CATS are the easyest of all if you need to retime them.The injection pump is loosened , a pin is installed , the pump locked down and the pin (a drill bit of the proper size) is removed.

*

GET DA BOOK!!!!!


-- Edited by FF on Friday 27th of January 2012 08:30:44 AM
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Old 01-29-2012, 09:33 PM   #36
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3208 n.a. coolant leak

I was talking before about a snow ball well here goe's

From a coolant leak to a rebuild of the entire cooling system.

to replace the water sleeve*I had to pull the heads.

a few pic's of my weekend activities.

1*remove exhaust manifold. #2 manifold removed.#3 remove rocker arms. #4 remove rods. #5 the injectors. #6 clamps that hold the injectors. #7*injectors removed. #8 head removed.*

On that last pic you can see the lady's foot I used to remove the injectors. I don't want to bore anyone but if there is any intrest*I can describe this top end rebuild as*I go along. *I am doing most of the work myself.

*I will be doing a valve job. After discovering 3 exhaust and one*intake valve to be leaking.

As long as I had the heads off. I did a little test to check the valves.

By spraying some break clean around the face of the valve. I used a*small shop vac* set on blow to blow air into the exhaust port. The same for the intake port. Bubbles were produced by the leaking valves.

I don't know yet if I can just lap them or if they need to be reground. I will pull the valves next.

SD

The injectors showed a few abnormalities in the spray pattern on the surface of the heads.





*



-- Edited by skipperdude on Sunday 29th of January 2012 10:54:28 PM



-- Edited by skipperdude on Sunday 29th of January 2012 10:54:53 PM


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Old 01-30-2012, 04:48 AM   #37
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RE: 3208 n.a. coolant leak

It is a good idea to check the valves for leaks after their service.

Level the head and fill each combustion chamber with diesel.

If the chamber stays full, its reinstall time.
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Old 01-30-2012, 10:21 AM   #38
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RE: 3208 n.a. coolant leak

Hi, I've been following your thread and saw the pictures this morning. The shot of your exhaust manifold seems to show that the manifold does not have the Cat riser bolted to it. It looks like there is a direct connection of the exhaust hose to it. Could you tell us or show pictures of the rest of the exhaust system in your enginne room. Since the Cat risers seem to be a source of concern with the NA engines your setup looks very interesting. Getting rid of them would be a wellcome alternative. Thanks.
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Old 01-30-2012, 10:58 AM   #39
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RE: 3208 n.a. coolant leak

Quote:
gordytwo wrote:
Hi, I've been following your thread and saw the pictures this morning. The shot of your exhaust manifold seems to show that the manifold does not have the Cat riser bolted to it. It looks like there is a direct connection of the exhaust hose to it. Could you tell us or show pictures of the rest of the exhaust system in your enginne room. Since the Cat risers seem to be a source of concern with the NA engines your setup looks very interesting. Getting rid of them would be a wellcome alternative. Thanks.
*There is the rub.

I don't have them. I have a dry stack exhaust.

Right off the end of the exhaust manifold to a cross over and up through the roof.

SD
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Old 01-30-2012, 08:49 PM   #40
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RE: 3208 n.a. coolant leak

skipperdude wrote:
I don't want to bore anyone but if there is any intrest*I can describe this top end rebuild as*I go along. *I am doing most of the work myself.
__________________________________________________ _____

Please continue with the details including pictures.* I've a 3208NA and am very interested.* And thanks for sharing.* Unfortunately I don't have any expertise to share with you.* Would if I did.*

We had the injectors replaced on Figment when we purchased her.* No maintenace records from the PO and ~4500 hours and wanted to know where we were.* May have wasted the $s and will likely never know.

DWG

Figment - KK48NS

*

*
*
*
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