Boat Engines almost never wear out
- they fail from improper operation & inadequate maintenance!
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A reliable engine is essential for your safety on the water
Are you confident that your engine is in good shape?
Or are you just crossing fingers that it will not fail at the worst possible moment?
"If it ain't broke, don't fix it" is often bad advice when it comes to boat engines.
Instead, you should focus on "preventive maintenance"!
A few hours a year of preventive maintenance can give you 5,000-10,000 hours of troublefree engine operation.
On the other hand: If you neglect this, you risk premature engine failure.
This not only leads to major repair bills: An engine failure - at the wrong time - can also endanger your boat and crew.
Proper engine maintenance is not rocket science. But it involves more than an occasional oil change.
"Knowing how to take care of your engine is not only good seamanship. It is also extremely satisfying."
- Nigel Calder, BoatHowTo Co-Founder
According to the 2022 US Coast Guard Recreational Boating Statistics, 207 significant accidents with 49 injuries and 12 deaths are directly related to failures of the propulsion system!
Almost 40% of all rescue missions conducted by the Royal Netherlands Sea Rescue Institution were due to engine problems. When excluding causes such as navigation errors, bad weather, and sickness, engine problems were the reason for almost 70% of rescue missions due to technical issues!
Some Expensive Examples for Maintenance Related Issues
Below are a few examples of mistakes and maintenance neglect that we see all too often.
All of these could have been prevented with proper maintenance.
Damage from Poor Fuel SupplIES AND INADEQUATE FUEL MAINTENANCE
By far the most common cause of engine trouble is poor fuel supplies and inadequate onboard maintenance. This not only clogs filters. It leads to expensive injection pump and injector damage. Especially with modern common rail engines.
Do you have water or bacteria in your fuel tank? Do you know what fuel filters to choose to protect your injectors from damage?
Hint: It's more than just their nominal micron rating...
Average cost for replacing a fuel injector: $700
Total cost for a 4 cylinder engine:
~ $2,800
Pitting corrosion on a Bosch fuel injector nozzle tip
Total loss from IMPROPER InstallationS
On almost all sailboats and many powerboats, if your engine is not properly installed it is at risk of seawater flooding. It may work fine for a few years, but once the raw water pump impeller wears or loses vanes, engine flooding is an ever present possibility. If you are lucky, you can flush the salt water out of the engine. If not, you end up with massive corrosion and/or mechanical damage. It happens far too often!
Do you know whether your raw water cooling and exhaust systems have been installed in a manner that prevents sea water intrusion?
Cost for flushing an engine:
~ $2,000
Replacement costs in case of total loss: $10 to $50k
This engine was installed without a siphon break with a risk of saltwater flooding. It also suffered from a general neglect of maintenance
Devastating Corrosion Damage
The raw water system of your engine contains warm to hot sea water, which is corrosive. Depending on the complexity of your engine, this water flows through various heat exchangers before reaching the exhaust elbow.
Even if the sacrificial anodes in this system are regularly replaced (which is not always done), corrosion issues are still not uncommon. In particular, with heat exchangers that incorporate galvanically incompatible metals (such as cupro-nickel and aluminum).
Do you know whether your heat exchangers (in particular intercoolers) are on the high-risk list of corrosion issues? When was the last time you took them apart to clean them and check for signs of corrosion?
Cost for a new intercooler: ~ $1,500 to $4,000
This intercooler core corroded into an aluminum case. This is not salvageable
Carbon Buildup Ruining Engines
If a mechanically injected engine is subjected to a duty cycle with short run times at light loads (very common, in particular with sailboat engines and generators), poor combustion leads to carbon formation.
This not only leads to decreased performance through fouling of the exhaust system. It also significantly reduces the lifespan of the engine and in some cases can require a total rebuild in less than 1,000 hours of operation.
Do you know how to run your engine to ensure full combustion and minimize carbon formation?
Cost for an engine overhaul: ~ $4,000-$8,000
This sailboat engine has 700 hours on it and already requires a total rebuild
The Good News: Engine Maintenance is not Rocket Science!
With a bit of time and dedication, everyone can learn how to take proper care of their engine.
Learn how to prevent these issues and many more:
Check out our latest BOATHOWTO production:
The Ultimate Marine Diesel Engine Maintenance Course
with Nigel Calder & Dr. Jan Athenstädt
Learn All You Need to Know About Boat Engines
In 63 lessons with over 11 hours of video content we take a deep dive into boat mechanics.
This is by far the most comprehensive online resource you will find on the topic.
And yet, you don't need any pre-existing knowledge!
All you need is a commitment to learning and the willingness to give your engine the care it deserves.
Special launch offer: Enroll now and get $50 off!
What You Get When You Sign Up
We continiously improve and expand our content based on your feedback.
Here are a few examples of our animated graphics from the videos and lecture notes
(click on an image to enlarge)
Why you should Sign Up Now
Stay Safe on the Water
A reliable engine is crucial to a boat's safety at sea. Imagine entering a harbor in heavy seas on a lee shore and your engine quits a few feet from the breakwater!
Save 1,000s of Dollars, Pounds or Euros
Good diesel mechanics are expensive - and hard to find! If you learn how to maintain (and troubleshoot) your engine yourself, over time this will easily save you four-digit fees.
Be Self-Reliant
Knowing your engine and being able to troubleshoot it can mean the difference between a wonderful vacation - or a few weeks at the boatyard.
Master your Systems
Obtaining a deep understanding of your boat's systems is not only empowering. It can be fun as well! Diesel engines are fascinating pieces of equipment. Learning their intricacies will make you appreciate the decades of engineering and gradual improvements that make them the reliable companions they are today. (If they are treated well!)
What experts say about BoatHowTo
Gio & Julie Capelli
ABYC certified Offshore Cruising Consultants
I can't recommend Boathowto enough!
The self-paced learning format is a game changer, allowing learners to tailor their educational
experience to fit their individual schedules and lifestyles. The depth of content provided fresh insights,
even for those of us with professional training.
Mike Beemer
Marine Systems Teacher at Skagit Valley College
Anytime students want more, I steer them to your site
The teachers are knowledgeable, and very well organized. You start from the basics and progress at a perfect pace! The presentations are very professionally done. Organization of topics is great with illustrations and a comment section.
Dan Lindner
Lead Instructor, Marine Systems at IYRS School of Technology & Trades, Rhode Island
Thanks for all your hard work and creating such great content!
Adding the BoatHowTo content to our electrical curriculum really helped us get the students a leg up on understanding the core concepts of marine electrical. I feel it especially helped our younger students learn the material in a way that was more familiar to them.
What we Cover in this Course
Click on the modules to show the individual lessons.
Introduction
MODULE 1
In this introductory module, we delve into the essentials of diesel engine maintenance, covering safety, routine upkeep, and practical tips for longevity and reliability in marine diesel engines.
About This Course
In this first lesson, we introduce you to our virtual engine workshop, and explain why we think this course is important for every boatowner.
How to Use this Course
We cover some practical details about the course, explain how to navigate through the content, and give you tips for an optimal learning experience.
Safety Precautions
This lesson emphasizes the paramount importance of safety in diesel engine maintenance, covering precautions around running engines, risks of burns and injuries, the necessity of hearing protection, and the dangers of heavy lifting and battery maintenance.
Maintenance & Overhauls
We discuss the importance of systematic maintenance scheduling for marine diesel engines, emphasizing the use of hour meters, record-keeping, understanding limitations for major overhauls, and the significance of using quality parts for reliability and safety.
Diesel Engine Basics
MODULE 2
In this module, we cover fundamental diesel engine principles, including core operating mechanisms, the evolution and functioning of various injection systems, cooling systems, turbochargers, and emissions reduction technologies.
The Combustion Process
In this lesson, we introduce the core operating principles of diesel engines, the functions of the main components, and the unique aspects of diesel fuel combustion, setting the stage for deeper exploration in subsequent lessons.
Conventional Injection Systems
We explore conventional diesel injection systems, explain their mechanisms and types, the importance of precise engineering, and differences between direct and indirect injection.
Engine Operation
We learn about the four operating cycles of a diesel engine - intake, compression, power, and exhaust - and the importance of timing and coordination for efficient engine operation.
Engine Cooling
We explain how to manage excess heat from the combustion process through water cooling systems, and briefly cover the distinctions and maintenance implications between wet and dry cylinder liners.
Turbochargers
We learn how turbochargers enhance engine power by increasing air intake and oxygen, the intricacies of their operation and maintenance, and the trade-off between increased power and reduced engine life expectancy.
Reducing Emissions
We address how legislation has forced innovations in emissions reduction technologies, and the implications of these complex systems for engine maintenance.
High Pressure Injection Systems
We discuss the evolution and benefits of high-pressure fuel injection systems, and the limits they impose when it comes to DIY maintenance.
Marine Engine Installations
MODULE 3
In this module we make sure our engine is properly installed, which is the basis for safe and reliable operation. We cover engine access for maintenance, engine mounts, fire fighting equipment, installation requirements for raw water cooling systems, and exhaust installations, as well as fuel systems and air supply.
Engine Access
We emphasize the importance of proper engine installation and run through a list of the engine parts that need to be accessible for maintenance.
Engine Mounts
We examine engine mounts and their crucial role as the connection between the engine and the boat, and learn how to inspect and maintain them to ensure optimal engine alignment.
Fire Fighting Equipment
We explain the U.S. Coast Guard's and the ABYC's installation requirements for firefighting equipment in engine compartments, portable and fixed fire extinguishing systems, and the importance of choosing the right type of extinguisher and ensuring proper installation to prevent accidental activation and potential engine damage.
Raw Water Cooling Systems
We talk about installation requirements for seawater cooling circuits and learn about the importance of using the right type of suction hoses and the installation of a siphon break to prevent saltwater flooding of the engine.
Exhaust Installations
We cover the importance of exhaust system geometry in preventing seawater flooding of the engine, and address the risks associated with carbon monoxide poisoning if the system is not properly installed.
Hose Clamps
In this short lesson, we emphasize the importance of using high-quality, corrosion-resistant hose clamps and how to select and install them.
Fuel System
We cover essential installation requirements for fuel systems to prevent leaks and environmental hazards, the importance of using appropriate materials for fuel tanks and hoses, and the requirements for primary and secondary fuel filters.
Air & Noise
In this short lesson we highlight the importance of ensuring an adequate flow of dry air to the engine compartment, which often conflicts with the need to minimize engine noise.
Fuel
MODULE 4
Contaminated fuel is the single most common source of engine problems on boats. In the three chapters of this module we take a deep dive into fuel cleanliness and fuel filtration and learn how to change our fuel filters.
Fuel System Introduction
In this overview of the chapter, we provide an introduction to the fuel system and discuss why you should be absolutely anal about ensuring your engine gets clean fuel.
Fuel Properties
We discuss the changes in diesel fuel properties over the last several decades, focusing on reduced sulfur content and the introduction of biodiesel, both of which can have significant impacts on engine performance and fuel stability.
Fuel Contamination
We get to know the two most common sources of fuel contamination in boats, water and biofouling, and learn about strategies for prevention and detection.
Tank Sampling
We introduce methods for fuel tank sampling, which is the single most effective way to prevent significant contamination from reaching your fuel filters.
Fuel Treatment
We discuss the use of biocides and biofilm dissolvers for treating contaminated fuel, while cautioning about their proper application and potential side effects.
Tank Cleaning
This lesson covers methods for cleaning heavily contaminated fuel tanks, including using borescopes for inspection and various cleaning techniques.
Particle Counts
We learn about the most damaging particle sizes for different fuel injection systems, discuss why we need multi-stage fuel filtration, and introduce the ISO 4406 standard for quantifying fuel contamination.
Filter Ratings & Limitations
We explore how fuel filters are rated, their limitations, and the challenges of filtering out small particles that are damaging to high pressure common rail engines.
Water Separation
In this lesson, we examine the methods and effectiveness of removing water from diesel fuel.
Primary Filter Setups
In the final lesson in this chapter we discuss various setups for primary fuel filters, stress the importance of proper filter maintenance, and provide practical advice on filter change intervals.
Changing Primary Filters
We learn how to change various types of primary filters.
Changing Secondary Filters
In this lesson we learn what to look out for when changing secondary filters.
Priming Filters & Bleeding the Fuel System
After a fuel filter change, the fuel system contains air which may prevent the engine from running. We learn how to bleed the system to get rid of this air.
Lubrication
MODULE 5
In this module we explore the oil system in our engine, learn how it works, get to know the different types of oil and oil filters, talk about oil change schedules, and describe practical steps for changing engine and transmission oil.
The Oil System
We provide an overview of the engine's oil system, explain its basic components such as the oil pump, filter, and pressure relief valve, and emphasize the importance of regular maintenance for engine longevity.
Oil Filters
We discuss the critical role of oil filters in engine longevity, explain how they function, the significance of micron ratings, and the necessity of selecting high-quality filters to prevent engine wear.
Oil Change Schedules
We focus on when, and how often, to change your engine oil, taking into account different factors such as engine use patterns and fuel sulfur content, and highlight the importance of regular oil analysis for early problem detection.
What Oil to Use?
We delve into different types of engine oils, explain the American Petroleum Institute (API) classification system, the importance of choosing the correct oil viscosity and type for specific engine requirements, and the pros and cons of synthetic oils.
Oil Change
In this lesson we provide a practical guide to changing engine and transmission oil, including tips on extracting old oil, replacing oil filters, and refilling with new oil.
Cooling
MODULE 6
In the two chapters of this module we discuss the maintenance of the raw- and freshwater cooling systems, which are vital for dissipating heat generated during combustion.
Raw Water Circuit
We discuss why we need the cooling system, explore the raw water circuit, learn about heat exchangers, and special cases such as direct seawater cooling and keel coolers.
Raw Water System Maintenance
We discuss the need for regular maintenance of the raw water system, including the importance of cleaning strainers and ensuring the functionality of impeller pumps to prevent overheating and potential engine damage.
Impeller Change
We learn how to change the impeller in the raw water pump and discuss the maintenance schedule for this crucial item.
Sacrificial Anodes
We discuss the crucial role of sacrificial anodes in preventing corrosion in the raw water circuit, and the importance of regular checks and replacements.
Descaling Heat Exchangers
We cover the maintenance of heat exchangers, including descaling to ensure effective heat transfer, and inspection for corrosion or scale buildup.
Siphon Breaks
We explore the function and maintenance of siphon breaks, which are a small but crucial piece of kit for preventing seawater flooding of the engine.
Exhaust System
We examine the maintenance of the wet exhaust system, including the inspection of exhaust injection elbows and waterlift mufflers for signs of carbon buildup or corrosion.
The Freshwater Circuit
We introduce the freshwater cooling system and highlight the importance of maintenance for the drive belt, and regular antifreeze replacement.
Freshwater Pump Belt Maintenance
We detail the maintenance of the freshwater pump's drive belt, including tension adjustments and checks for wear or misalignment.
Types of Antifreeze
We discuss different types of antifreeze and their chemical compositions, and emphasize the importance of using the correct antifreeze and not mixing various types.
Changing the Antifreeze
We provide a step-by-step guide on how to change your antifreeze, including draining, flushing, and refilling processes.
Air
MODULE 7
We explore the air system of diesel engines and follow the journey of the air from the engine room through the engine's air inlet and any turbocharger and intercooler all the way to the engine exhaust outlet.
Air Supply
We explore the volume and temperature requirements of intake air, guidelines for engine room ventilation, and various types of air filters.
Crankcase Ventilation
We focus on the function and maintenance of crankcase breathers, exploring different types of varying complexity and their role in preventing pressure buildup and oil mist pollution.
Air System Maintenance
We cover the maintenance of air filters and crankcase breathers, and highlight the importance of regular checks to prevent engine performance issues.
The Exhaust Side
We address the flow of air post-combustion, the importance of preventing carbon buildup in the exhaust system, and the management of turbochargers and their wastegates.
Drive Train
MODULE 8
We explore various transmission configurations and the maintenance of drive trains from the connection with the engine's output shaft through to the propeller that's driving the boat.
Damper Plates
We examine the role of damper plates, their function in absorbing shocks and vibration, and how to replace them if necessary.
Transmission Configurations
We explore different types of transmission configurations, including planetary and two-shaft gears, and the nuances of their operation and maintenance.
Clutches
We focus on the two main types of transmission clutches - multi-plate and cone clutches - and talk about their operation and common wear-and-tear issues.
Transmission Maintenance
We discuss the importance of regular transmission maintenance, including oil level checks, oil changes, and inspecting the operating mechanism to ensure smooth transmission function.
Couplings & Joints
We cover the critical aspects of propeller shaft couplings and joints in the drive train, including their alignment, maintenance, and troubleshooting tips for common issues.
Stuffing Boxes
We address traditional shaft seals, known as stuffing boxes, including their types, maintenance, and replacement techniques.
Dripless Shaft Seals
We introduce modern alternatives to traditional stuffing boxes, such as face seals and lip seals, and detail their advantages, installation, and maintenance.
Shaft Bearings
We focus on shaft bearings, particularly rubber sleeve ('Cutless') bearings, and discuss their role, wear signs, and replacement procedures.
Propeller Installations
We explore the intricacies of propeller installations, including general selection criteria, installation techniques, and maintenance tips to ensure optimal performance.
Saildrives
We examine the unique features and maintenance requirements of saildrives, and highlight their benefits and potential issues, particularly with respect to galvanic corrosion.
Bonus
Nigel's Expert Guides for Digging Deeper
Apart from the regular lessons of this course, you will have access to an ever increasing collection of bonus guides.
Engine Work
In this bonus module we delve deeper into work on the engine that goes beyond regular maintenance.
Chapter 1:
TOOLS & SPARES
Tips and recommendations for the perfect kit of tools and spare parts, depending on your cruising plans and ambition.
Chapter 2:
TROUBLESHOOTING
Even with the best preventive maintenance, we may sometimes run into trouble. In his troubleshooting guide, Nigel explains how to fix the most common engine problems.
Chapter 3:
EXTENDED LAYUPS
When you lay up your boat, there are a number of things you should do to preserve your engine. In particular when you winterize your boat in below-freezing temperatures.
Chapter 4:
VALVE ADJUSTMENTS
Nigel gives you some tips about the valve adjustment process. On most modern engines this is not part of regular maintenance anymore, but depending on your engine, it may still be good to know how to do it.
Repowering a Boat
At some point, it will be time for a major engine rebuild. We discover ways to determine, when it makes sense to invest in a rebuild and when it is better to buy a new engine.
Sea Trials
If you buy a new boat, or after a major modification to the propulsion system, it is necessary to test your engine. We detail how to do this and what to look out for.
Engine Performance
We delve deep into performance curves, how to optimize fuel consumption and engine life expectancy, and the intricacies of the interplay between propellers, transmission ratios, and engine performance.
Meet Your Teachers: Jan & Nigel
The "Guru of Boat Systems"
Nigel Calder
Author of the Boatowners Mechanical and Electrical Manual, often just referred to as the "Bible for Boaters", and Marine Diesel Engines, one of the leading books on the topic. Nigel has worked with marine engines for more than 40 years. In our course you will get unprecedented access to Nigel's expertise as he guides you through the practical parts of maintenance on various demo-engines in the workshop.
The "Didactic Mastermind"
Dr. Jan Athenstädt
Jan is a full-time liveaboard with a PhD in computer science. Apart from his work at BoatHowTo, he runs an online shop for boat supplies in Germany.
Jan is producing the videos and guiding you through the lessons. He is also responsible for the 3D graphics and animations that will help you understand what's going on inside your engine.
What people are saying about our teaching style
We got a HUGE amount of raving feedback for presentation and teaching of the material in our Marine Electrical Courses.
And with practice and new tools for interactive graphics, our Marine Diesel Engine Course is bringing this to a new level!
Tony Smith
Student of our Boat Electrics 101 course
...exactly what I needed to develop a better understanding
On signing up to the 101 course I hesitated as I was not sure if online learning was for me. Also wanted to see if the content suited.
I must say the content style of delivery combining video, written and diagram has been excellent. This has fitted in well with other tasks while living on my 12m sailboat.
Nicola Catalano
Student of our Marine Electrical courses
Very interesting and challenging at the same time
Jan & Nigel show knowledge and passion for what they do with high proficiency and enthusiasm! The content is well done/explained and rich of details [and] there is always the possibility to go back and re-watch again !
Jonathan Mastin
Student of our Marine Electrical courses
I am thoroughly delighted
Smashing job of presenting the material and making it engaging. I have learned from and been entertained by every lesson so far, and I look forward to the next one each time. I'm SO glad I found you!
Hiring a Marine Mechanic for Maintenance can be Expensive...
...and Fixing Damage from Neglected Maintenance Even More So!
By doing things yourself you save hundreds of dollars in yearly maintenance fees.
Hourly rates for good mechanics easily range from $100 to $200, leading to as much as four-digit annual costs.
And by knowing essential preventive maintenance, you can save yourself from costly repairs than can easily reach five digit prices, depending on the size and model of your engine.
Sign up now to claim the launch discount
Except for course launches, we don't do discounts. This is the lowest price this course will ever be.
Sign up now
special launch price
Learn diesel engine maintenance the right way!
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100% Money-Back Guarantee for 60-Days
You are fully protected by our 100% Satisfaction-Guarantee. If you are not convinced by our course within 60 days of your purchase, just let us know and we'll send you a refund.
Sign up now to claim the launch discount
With the exception of course launches, we never do discounts. This is the lowest price this course will ever be.
Sign Up now
Learn diesel engine maintenance. The right way.
Frequently Asked Questions
We made this course with beginners in mind, so you don't need any pre-existing knowledge. However, we dive deep, so this is not a short "just tell me what to do" kind of course. We want you to do the maintenance steps we teach, but we also want you to understand why you're doing it.
On the plus side, once you have mastered what we teach in this course, you will understand what's going on inside your engine and will have the confidence to work on it yourself.
Probably. If you have the skills and knowledge of a professional mechanic, you will already familiar with a lot of the things we cover in introductory modules at the end of the course.
On the other hand, we provide a lot of background knowledge that goes beyond what you typically find in books or explanations of the various topics.
The best way to find out is to sign up. If you feel like the course did not provide enough additional value, let us know within 60 days and we will refund you. No hurt feelings!
No. You can take the lessons at your own speed and go back to a lesson anytime, over and over. While you can access any lesson as soon as you acquire access to the course, we recommend you follow them in order as they build on each other.
Unfortunately for now you must be online to watch the videos. We do however provide lecture notes for every lesson that also contain all the content. You can print out the HTML pages in your browser if you want to have a reference to the course material while at sea.
Another great resource to have on board is Nigel's ‘Boatowners Electrical and Mechanical Manual’ and his book on Marine Diesel Engines’! These are a great addition to our course content.
You can access the lessons from anywhere and watch the videos with your computer, tablet, or phone.
Yes! If you are not 100% satisfied with what you learned in our course, just send us an email within 60 days of your purchase and we will send you a refund.
We do not have dedicated office hours. But we will do our best to answer any questions about the lessons that you ask in the comments section of the lessons.
You have another question? Fill out the form below and we'll get back to you!
We are super excited about launching this course!
From the time we started BoatHowTo, our goal has been to one day create a course on diesel engines. But we did not want just any course. We wanted it to be the most comprehensive course out there and at the same time present it in an easy to understand manner.
In order to get the quality we were aiming for, Nigel went through hundreds of technical documents to write the lecture notes, Jan learned a new 3D modelling software to create graphics and interactive animations, and we both flew to Germany to film on actual engines at a boatbuilding school.
It took us two and a half years from the first drafts to the finished course. Much longer than we expected.
But we have finally reached our goal. We are confident, that we have created something unique and extremely helpful to many boatowners around the world.
We hope you join us for this deep dive into Diesel Engine Maintenance.
See you soon in our virtual engine workshop!