E40 Engine Refit
Date: November 9, 1997
From: Armand Zerilli zerilli@email.msn.com
I am considering re-powering my Endeavour 40 sail boat which is15 years old and has a Perkins 4-108 with over 9000 Hr. and Westerbeeke Generator 4kw with 3500 hr. . . . Both are running fine, however I'm intending to do some extensive cruising for several years and don't want to have breakdowns in far away places.
I have chosen to replace these diesel engines with a Yanmar 4JH2 50hp. and a Westerbeeke 5kw. The problem I'm having is that the old engines have 2" exhaust System. However, the Yanmar requires a 3" exhaust system . . . and will not warranty the engine with anything less . . . and I agree I don't want to damage the engine if this is their requirement. Because the way the boat exhaust hosing is configured . . . it is a major problem in changing one of the 2 hose to a 3". Its a 26 feet run going through bulkheads and various inaccessible places.
I'm looking for anyone who knows of anyone who has done a refit on an Endeavour 40 and how did they solve the 3" exhaust . . . or if they used a different engine . . . what make?? thanks Armand
Date: March 15, 1999
From: Armand Zerilli zerilli@email.msn.com
Paul, Last year I asked Endeavor owners on this forum:
"I am considering re-powering my Endeavor 40 sailboat which is 15 years old..I have Chosen to replace these diesel engines with a Yanmar 4JH2 50hp. and a Westerbeke 5kw. The problem I'm having is that the old engines have 2 inch exhaust System. However, the Yanmar requires a 3" exhaust system . . . and will not warranty the engine with anything less . . . . However, because the way the boat exhaust hosing is configured it's a major problem. . . It's a 26 feet run going through bulkheads and various inaccessible places. Does anybody know a way of getting around this problem"..
I did not get any response to my inquiry, and as a fool I went ahead and installed the Yanmar according to their requirements.
I thought I'd like to express my opinion to other owners that might be considering swapping out to a Yanmar that I would not opt to change the exhaust hose. Frankly, I do not think the old exhaust system would cause the back pressure to rise to a point that would significantly harm the engine. Another Endeavor 40 which I know the owners, had a reputable local yard install the same engine, using the old exhaust system, and is running just fine after 4 years. By the way they some how got Yanmar to warranty the engine (maybe because It was professional installed). I'd still not do It!!!.. even if Yanmar says they will not certify or warranty the engine.
The biggest problem I had was with the exhaust hose system. It's really a bear to change over to a 3" diameter tube especially in the Endeavor 40. I spent more time and effort putting in that damn exhaust system than I did replacing both engines (I also refit the generator)
Getting the engines in and out of the boat was much easier than I thought. We used a long boat dock davit and got them through the companion-way and through the engine room forward opening. I first striped the Perkins as best I could to make her lighter, and lifted It up using the steering pedestal (Edson) bolts above the engine to hang a vang.then placed 2X6s under pan and along the engine room floor and slid the engine forward by the use of a "come-along" tied to the mast . Then used the davit to lift It up and out. The Yanmar went in the same way and I only needed to remove the alternator to get her through the openings. Its quite easy to get her lined up with using the old motor mounts and some shims under them.
The Yanmar is a perfect retrofit for this boat. Its by far a better, quite, cleaner, more efficient motor than the Perkins. It's a true 51Hp engine (Perkins is only 37 @ the shaft) which will give you greater thrust and about more knots using the same prop and RPMs. And because It will run at 2800RPM you'll make up till 8+ knots with out overheating.
Date: February 17, 2003
From: David Meuche starstream@verizon.net
Should anyone be interested, I repowered our E40 with a Yanmar 4jh3 56 hp engine about a year and a half ago. It was a great improvement over the Perkins 4108. I would be happy to share my experience with anyone who is considering a re-power.
Date: March 6, 2006
From: David Meuche starstream@verizon.net
About 3 ? to years ago we re-powered our 1981 Endeavour 40. We selected the Yanmar 4JH-3. It is a normally aspirated 56 HP engine and is slightly lighter than the old Perkins 41-08.
The Perkins came out without any problems. We have a generator and therefore we have an opening to the engine compartment immediately under the companionway ladder in addition to the doors to the compartment on the port side of it. The generator was removed through the forward opening and the engine followed it right out of the same opening.
The Yanmar requires a larger exhaust hose, 4 inch as I remember, and a larger exhaust through hull. It also needed a larger seawater strainer intake through hull. The 4 inch hose just fit through the space where the blower hoses exit the engine compartment to port. (between the aft bulkhead of the galley and the forward bulkhead of the aft head. An elbow was required in the aft head where the exhaust hose turned aft. We cut an opening just above the shelf in the head in the port side wall and the forward bulkhead of the head to allow access to install the elbow. After it was very easy to cover the opening with some teak veneered plywood and trim after the installation.
We had custom engine mounts built and a custom stainless exhaust elbow built for the engine. It then mounted on the existing mounting platform/oil pan molded into the engine compartment.
The sea trial showed that we needed to remove about 2 degrees of pitch to achieve the max rated 3,600 rpm’s on the engine. This engine cruises at about 2,800 to 3,000 rpms.
The noise level is quieter than the Perkins was and there is less vibration as well. The temperature in the engine compartment, when the engine is running also runs 40 to 50 degrees cooler that it did with the Perkins. A much more efficient water jacket seems to be the reason. Yanmar wants/allows you to run the engine wide open at least 10% of the time to keep the cylinders clean. When I do that we see 8.4 knots. Normal cruise is around 6.5 to 7.0 knots and we burn around .8 GPH.
Our engine has now 670 hours on it and except for a small oil leak on the oil pressure transmitter, easily fixed, it has been flawless. Are we glad we did it? Very! Would I change anything? Not a thing. Our installation was done in St. Petersburg, FL and I would use the same installer again and recommend him in a minute. Mark Donaldson, MD Marine Services 727 455-1171. He has been at it for a long time. Now, for the money. When I did this 3 to 4 years ago the engine was slightly less than $7,000. The other “stuff” and labor I am guessing was about $3,000 to $3,500.
I don’t think that Yanmar is selling the 4JH-3 any more but know that they have a newer model of the same or a similar engine.
This is important! When the engine is out is a perfect time to do a great many things. We pulled the pedestal to use the hole where it was, to raise the engine for removal and installation. I decided to overhaul it and to replace all of the instrumentation then. I also replaced the water heater and generally tidied the engine compartment up. Replaced fuel lines, water hoses, re-routed some wiring and on and so on. Anything you can think of that you have on a wish list that is in or passes through the engine compartment is about 6 ? times easier to do when the engine is removed.
If I can help anyone with this don’t hesitate to email or call. I could take pictures of some of this to be emailed if that would help.
