One of our Lehman's is starting to put out a lot of gray smoke and start
rather reluctantly so I thought I would try to remove the injectors and
have them serviced. I'm not a mechanic but I have a moderate level of
mechanical skills. I'm looking for some advise on how difficult a job this
is. I have the Lehman manual and they show a special tool for removing the
injectors but I have been told that you can use 2 screw drivers to pull
them out. I have no idea when the previous owner had the injectors
serviced, if ever.

Is this a difficult job? Is it recommended that I have the special tool for
removing the injectors or just use a pair of screw drivers? Should I remove
the injector pump and have it serviced also? How difficult is it to time
the pump when it is reinstalled? Does anyone have first hand knowledge of a
service shop in the Anacortes or Seattle area that they would recommend?

On our last boat we had the injectors and pump removed by a mechanic and he
took them to a shop in Bellingham for service. He had to return 2 of the
injectors that came back bad and the pump had to be sent back 3 or 4 times
before they got it right. Needless to say I don't want to go through that
again. This time I thought that I would remove and reinstall the injectors
myself (what's that about if you want something done right...) and find a
better shop to service them. Does Doc's in Seattle service them or do they
send them to an outside shop?

Thanks for your advice, opinions, etc.

Frank Osborne
'Island Fever', 44 Defever
http://www.OsborneConsulting.com/IslandFever/IslandFever_Main.htm

I did this exact job last winter.  I did have help, though, as a friend had
been a diesel mechanic for tractors (Case & John Deer), but he had never
seen or heard of a Lehman.  We didn't have the special tool.  He wiggled
them out carefully with screwdrivers.  I have a manual and we followed it!
Took all of the fuel lines off as assemblies as they are clamped together
for support.  Cleanliness is essential.  Use paper towels instead of rags.
Make sure everything is clean before you start.  We also pulled the pump.
As I recall we put the engine at top dead center, then removed the pump.
This made timing easy when we reinstalled the pump.  Make sure you protect
all of the injector openings and the pump opening with paper towel coverings
to keep dirt out.

This is not a job you're going to do in an afternoon, so don't try to
squeeze it in and rush through it.  We spent all day and I had some
experienced help.  I also only have one engine, so working space was not an
issue.  Without the help I would have attempted the job myself, since I have
a manual to follow, but I know it would have taken longer.  If you are
unclear about anything in the manual do not hesitate to call American
Diesel.

I shipped the injectors and the pump to American Diesel.  They do not
perform the repairs, but there is a local shop they deal with and trust that
does.  I fabricated a wood box to ship the pump in.  They found a problem
in the pump and it turns out only five cylinders were operating because of
it.  I was very happy with their service (and the results!).  I started
this job in December, so I had plenty of time to remove the parts, send them
out, have them repaired, wait for their return, and get them reinstalled.

Good Luck,

Andy

Andy & Linda Woods
Grand Folly
1970 Grand Banks 36 Classic
Georgetown, MD
awoods@surfbest.net