That’s how Ann described me today, when the new parts were installed and the engine still would not start. Going further she volunteered that it might be best if she went and did something else to stay out of the line of fire.

Injection pump cleaned up and ready to install. Cross fingers!

Manifold and new gasket (thanks to friends on "Bright Angel")
Yup, the parts arrived yesterday afternoon around 1400. I decided it would be OK to spend a little time installing at least some of them, and then finish today when I was refreshed. The plan sorta worked. I DID install the fuel injector pump, the four injectors, the intake manifold, air filter, dipstick, throttle cable and some other stuff. In fact I was in “The Zone” in that I remember looking at the clock around 1600 and then next thing I knew it was getting dark! Time to quit for the day.
So…today, the plan was to finish the installation and fire up the engine. Yeah, right. I was awake half the night still worrying about the timing issue. I actually have almost figured it out, but have not yet really found a good explanation of how to guarantee the timing is set correctly when you reinstall the pump onto a timing gear that is still in the engine and you send it out for overhaul. How is it timed when it comes back? I DID write a note that I removed it at #1 TDC, but the tech’s Hindu is a bit better than his English, and my Hindu is non-existent. Let’s just say I was 75% confident that the thing would work. That leaves 25% confident that Charisma would blow up when everything was installed and I turned the key. In fact I was so worried, Ann convinced me we should call her brother Paul in the US, who is a mechanic. He was extremely helpful in helping me sort out my concerns and kind as well, considering we called him at 0100, forgetting that he lives in Denver, not the West Coast!
So, fast forward past my nightmares to today. I finished installing the last fuel hoses, checked everything I installed, made sure there were no “mystery parts” still sitting in the parts bucket and prepared for the big moment.
“ANN, it’s time”. She has been working on cleaning the stainless and the hull and was out in the dinghy scrubbing the waterline. Back in the cockpit, I instructed on how we were going to do the start. Ready? go. rurrr, rurrr, rurrr, and nothing.
Honestly, I wasn’t really expecting it would start the first try. But we tried a couple more times with some adjustments to throttle and fuel pump and nothing! Rats! I was afraid the timing might be so far off there was no combustion. There was nothing else for it but to break for lunch. And think about this perplexing problem. And have a beer.
Over lunch, I decided if it was timing, we would at least be getting some ill-timed engine explosions. What else could it be? Has to be fuel. After lunch, I started tracking the fuel feed and found….we weren’t getting any to the engine. Hmmmm. No Bueno.
So two hous of troubleshooting later, I decided we were down to the fuel lift pump. I took it off the engine and started to disassemble it when I realized that if it was in fact broken, I couldn’t possibly find the parts here and we would be at least another week waiting for a shipment from NZ.
What to do.
Fortunately, we had Saint Bob of Bright Angel who was anchored nearby. He has a very similar engine (in fact we have already borrowed a manifold gasket from him). Living up to his boat name, Bob had a spare of exactly the right fuel lift pump! Hallelujah! I dinghied over and negotiated that I would get another shipped here or give him my right arm in exchange and he kindly parted with this golden of all parts in the midst of our darkest day.
Once back on Charisma I installed the new lift pump, bled the fuel filter and injector pump and had Ann once again get ready to crank the engine. “OK, crank ‘er up!”. Once again, Ann cranked the engine. Nothing. OK, we can do this-I cracked off the injector nuts to bleed the injectors and had Ann crank the engine again. After a moment, diesel fuel spewed everywhere across the engine (as it’s supposed to when you bleed the lines). STOOOOPPP! She stopped, while I tightened the injectors. OK, try it one more time. This time Charisma’s diesel came to life-yippppeeeee! A rattling, noisy, clanking thing never sounded so good.
We let her run for a while to warm up and all systems seem go. She’s purring like a kitten. No smoke, no drama. For now, we have engine.
OK, so I may not be a full-on diesel mechanic (yet), but I smell like one.