A Look into Marine Engineering

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Gabriel Hasl
Capstone Paper
Functions and Parts of Boat Engines:
A Look into Marine Engineering
10/19/15

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Author Notes

During the summer of 2015, I worked with Ralph Stewart, a mechanical engineer, at the
Volvo Penta located in Virginia. I spent 70 hours shadowing Mr. Stewart at the Volvo Penta
facilities. Special thanks to my parents, Ralph Stewart, the employees at Volvo Penta, and Mrs.
Graves. My email: gopackarod@gmail.com

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Appendix
Introduction: Page 4
The Search: Page 6
Product: Page 10
Results: Page 12
References: Page 15

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Introduction

We all heard of the recent Volkswagen controversy. This was a problem concerning ethics
in the engineering field. Volkswagen felt the better option for them was to falsify their vehicle
emission results in order to increase revenue without needing to alter their products. This was
eventually discovered by the EPA, (Environmental Protection Agency) and they issued a notice
of violation of the Clean Air Act to Volkswagen. They found that Volkswagen sold eleven million
cars worldwide that failed to meet their standards. As a result of Volkswagens misdoings, they
announced they would pay 7.3 billion dollars on remedying their emission issues.
Engineering has been vital to human survival for the entirety of recorded human history.
From bicycles to present-day renewable engines, mechanical engineering has impacted human
civilizations since 6000 BC. Now, engineering influences humanity more than most other fields,
due to its massive outreach across the world. Engineering started from the first wooden boat to
bicycles, to combustion engines, and eventually to electrical and fuel engines. Mechanical
engineering, a sub-field of engineering, emerged during the first industrial revolution in Europe
during the 18th century. Today, mechanical engineers use these core principles along with tools
like computer-aided design, and product lifecycle management to design and
analyze manufacturing plants, industrial equipment and machinery, heating and cooling
systems, transport systems, aircraft, watercraft, robotics, medical devices, weapons, and others.
Mechanical engineering has continually evolved to incorporate advancements in
technology, and mechanical engineers today are pursuing developments in such fields
as composites, mechatronics, and nanotechnology. Mechanical engineering overlaps
with aerospace engineering, metallurgical engineering, civil engineering, electrical engineering,

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manufacturing engineering, chemical engineering, and other engineering disciplines to varying
amounts.
I want to study the field of mechanical engineering, because I am interested in
combustion engines, and finding more efficient techniques for mechanical advancement.
Combustion engines fascinate me because they are used in everyday life and because a very
small percent of people understand how they function, and how they can be enhanced from what
we use today. In order to keep earth survivable, humanity needs to make sure that pollution
standards are not exceeded and that engines are as fuel efficient as possible.
Sophomore year, I started my research of mechanical engineering as related to
marine/boat engines. I researched the different type of boat engines, the functions of these
engines, and quickly identified that I find great interest in researching this field. For this reason, I
applied for a mentorship position at Volvo Penta, a manufacturer of marine and industrial engines
and power systems.
My overarching question is the following: What are the basics of mechanical marine
engineering, and what would working as a mechanical engineer entitle? From this I derived a
few sub-questions. What are the main types of boat engines commonly used today? I ask this
question because it connects to my main question and the answer to this question will help
simplify which boat engines I need to know for my study of marine engineering. My second subquestion is: How do inboard engines work and what are the functions of the individual parts that
make the engine run correctly? In order to work as a mechanical marine engineer, I must know
the parts and functions of boat engines. Volvo Penta specifically produces inboard engines, so I
shaped my question around the experiences I would encounter and learn from.

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The Search
During the summer of 2015, I shadowed under Volvo Pentas mechanical engineer, Ralph
Stewart. Every day at Volvo Penta, we were faced with a new challenge regarding boat engines.
Either something had malfunctioned in an engine and we had to locate the malfunction and fix it,
or we were told to remove parts from an engine and replace them with new parts. I also went to
their test center where they test their marine engines in boats on open water. I acquired my
mentor by asking my father, a Volvo Penta employee, if anyone was available to mentor me at
Volvo Penta. My dad connected me with their mechanic Ralph Stewart, and I sent him
engineering and general questions about the mentorship.
The search began on June 29th at Volvo Penta. I arrived at the mentor site around 7 in the
morning, and I was swiftly introduced to my mentor, Ralph Stewart. Mr. Stewart began with
showing me around the facilities, and introducing me to the workers at these different places
within Volvo Penta. There was the design department, testing department, commercial
department, inventory department, and finally the prototype department. After an hour of two or
introductions, we jumped right into our first project. Mr. Stewart told me that our task was to
work on a prototype for the factories in Lexington to use as a model. At first sight of the large V6
inboard boat engines, I was overwhelmed with interest about all of the parts names and
functions. Over the course of the mentorship, I learned all the vital parts to the V6 and V8
inboard boat engines.
During my mentorship, I participated in many of their daily and specialized meetings.
These meetings consist of the daily objectives and any questions the employees have for the
managers. After that we called the test center and they share anything they found from their

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overnight engine tests. Meetings were also held during the day for specific departments in order
to brainstorm and solve any problems.
We first worked on mounting prototype parts. This included the FEAD (front end
accessory drive), and accessories for monitoring the engine in case of overheating or low engine
liquid levels. We mounted and fitted an oil pan design on a 6.2 liter GDI (gasoline direct
injection) General Motor Marine engine. To do this, we lifted the engine onto an engine hoist and
moved it into a workplace. We then gathered the tools we needed to mount the oil pan. This was
done by screwing on the oil pan along the bottom of the engine after applying adhesive to the
corners of the metal pan. Afterwards, we installed the exhaust on the V6 GM engine for the dyno
(dynamometer). The exhaust manifold goes on the side of the engine, leading the exhausts from
the engine outwards. The manifold is cooled with water as the hot exhaust passes through the
metal chambers on both sides of the engine.
We then drove to their test center about forty five minutes away. They showed me where
they kept boats for testing on water and the locations of their testing apparatuses. There were also
rooms for meetings and large buildings where they kept spare boat frames used for testing
engines. We then boarded a newer boat, and drove it along the Chesapeake Bay. I even got a
chance to drive the boat, and I drove to speeds upwards of 60 miles per hour. Ending day 1, we
drove back to the Volvo Penta Engineering Center and installed the exhaust with the catalyst,
along with the PCD pump. Finally we prepared the engine to run.
On day 2, I helped build the complete master V6 engine from the long block to the
exhaust. All Volvo Penta engines start with GMs standard block engines, and are modified for
use in marine environments. These modifications include: the alternator, power steering pump,
circulation pump, oil filter, flywheel housing, engine mounts, exhaust manifolds, serpentine belt,

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starter, dipstick, catalytic converters, and the expansion tank. Components that are only used on
boat engines include: a raw water pump, heat exchanger, coupler, FEAD, flame arrestor, power
steering cooler, and PCDs. We took the GM V6 block and started adding the parts required for
marine use. This master engine would later be used as a model in the Lexington factory for V6s.
I helped build the complete master engine from the long block to the exhaust. This took the
entire second day to finish.
On the third day, we worked to put together and installing a mount height test stand and
engine. An employee at Volvo Penta was theorizing whether or not changing the exhaust
manifold between a V6 and V8 manifold would change the amount of water expelled from the
engine. Therefore, we built a test apparatus for water flow that differentiated between the two
manifolds, and recorded the amount of water flowing out the engine. There ended up being no
difference in water expelled between switching either manifold on the engine, so we concluded
that matching the manifold cylinders to the cylinder blocks was the best way to build the Volvo
engines.
On day 4, we started by working on a test rig for PCD work, and then mounted an electric
pump on the test rig to check the impeller (rotating component inside the pump). Afterwards, we
received a broken engine, and we moved it into the dynamometer, which is a device for
measuring the performances of an engine by recording force, torque, and power. First we
removed the timing cover, and did a V6 280 main component bracket fit up. Finally, we replaced
the timing tensioner on the V6 in the dyno. Mr. Stewart and I determined that the broken plastic
part in the timing cover didnt affect the performance of the engine after conducting multiple
tests on the engine. The results of the tests were recorded on computers connected to the
measuring devices inside the dynamometer.

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On the 5th day of the mentorship, we started by lifting a V6 GM engine onto a lift, and
moving it into a room we could work. We first removed the oil pan by removing all the nuts and
screws that held it together, and then installed a new oil pan and timing cover on the V6.
Afterwards, we brought in another V6 engine, and tore down the V6 240/280 with the bad #4
exhaust valve. This engine was then shipped back to GM to find the root cause of the problem
that led to the bad exhaust valve.
On day 6, Mr. Stewart and I started by replacing the connecting rod bolts in two
prototype 6.2 liter engines. Then we performed a multiple engine task. We finished the day
setting up manifold PCDs measuring the CG of a 6.2 liter engine. On August 4th, Mr. Stewart
and I disassembled an engine, prepping for a new FEAD replacement. We tore down the original
FEAD (front end accessory drive), and replaced it with the new FEAD when it arrived.
On the final day, a broken engine came into Volvo Penta, and Mr. Stewart and I found
that the oil cooler had scrapings left in the corners from when it was manufactured that led to a
buildup and eventual stoppage of flow through the oil cooler. Our plan of actual was to test other
newer engines to see if they had the same problem by dropping a small ball through and FEAD,
and seeing if it passed through the oil cooler.

Product
During my mentorship at Volvo Penta, I began thinking ahead of time for my final
product. I reckoned that the best way to exemplify my knowledge I acquired during my time at
the mentorship would be to bring in one of the marine engines and show the different parts and

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functions, but bringing in a full-blown marine V6 engine is beyond my capabilities. Therefore, I
thought of the second best option, and that was to build a model combustion engine to display its
parts and functions. After deciding on this idea, I looked into any possible model combustion
engines I could build.
Unfortunately, building gasoline combustion engines is impossible to do from scratch
without machinery, so I searched for any electric model representations of a combustion engine.
On the Smithsonian website, I saw that they sell electric models of combustion engines, so I
purchased the inline 4 model combustion engine. Building the actual engine took up the entirety
of Sunday November 15th. The model had hundreds of small parts, and it was extremely easy to
place parts on backwards. This lead to me having to undo what I had done, and placing them
back together in the right place.
I started by assorting the small parts into their separate categories for construction. The
first part I build was the pistol, and I then simulated this three more times. After assembling the
pistons, I mounted the pistons onto the crankshaft using connecting rod keepers. I then mounted
the oil pan on the lower housing of the engine, and installed the piston crankshaft assembly into
the cylinder block. To do this, I had to position the piston crankshaft assembly and the cylinder
block to carefully insert the four piston heads into their respective cylinders in the cylinder block.
After fully completing the cylinder block, I mounted it on the lower crankcase. This step is
where an assembler could easily reverse the orientation of either unit, which would lead to an
end result that doesnt function.
After completing the lower crankcase, I installed the springs on the valve stems, and then
installed the valves in the cylinder head. These valves serve as exhaust valves. Mounting the
rocker arms on the rocker arm shaft was my next task to complete, and this step also led to some

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confusion, because the orientation of the alternative position of the rocker arms. After finishing
the rocker arm shaft, I installed it into the upper cylinder head. Covering the upper lip of the
cylinder block, I screwed on the head gasket. After completing the lower cylinder head, I
mounted it onto the cylinder block. Assembling the camshaft was one of the hardest parts of this
model, because of the strict mounting sequence required to orientate the cams correctly. After
finally assembling the camshaft, I installed in on the lower cylinder head, and then attached the
upper cylinder head to the lower cylinder head. Finishing the cylinder block entirely, I attached
the rocker arm cover over the upper cylinder head, and mounted the timing gear on the
crankshaft. This gear serves as a means to regulate how much the crankshaft outputs per rotation.
Then I mounted the timing wheel on the camshaft using the alignment tool. Going with the
timing wheel, I mounted the timing belt, timing belt pulley, and the timing belt cover. Getting to
the lasts components, I installed the water pump, the fan belt pulley and fan, the crankshaft
pulley and fan belt, and the flywheel clutch. I then had to position piston 1 so that it is at the top
of its vertical travel when I install the distributor assembly.
Finishing the engine, I adjusted the ignition, installed the spark plugs, attached the drive
module, and attached the clutch cone to reduce noise. The final steps were to mount the
carburetor and intake manifold, install the dipstick, and install the exhaust manifold. Fortunately,
when I had completed the final process of building the model, it ran smoothly powered by
batteries. This model simulates what the insides of an inline 4 combustion engine would look
like, and what each part functions as. After completing my product, I showed and explained the
model to by summer mentor at Volvo Penta, Mr. Stewart. He applauded me on my work and we
took pictures together with the model engine. Mr. Stewart also had a few questions about the
model engine, which I answered from the knowledge I gained during the mentorship.

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Results
I left the mentorship knowing the answers to my sub-questions. Boat engines are put into
main two categories, outboard engines and inboard engines. Outboard engines are engines that
are detachable and can be attached to the rear of the boat. They are also portable unlike the
inboard engine. An outboard engine is a self-contained unit containing an engine, gear case, and
propeller. They can be used in any type of water, and have a wide range of horsepower per
engine. Outboard engines control the boat using a tiller that swivels the engine to direct the
propeller. There are two subcategories for outboard engines: two-stroke and four-stroke. The
two-stroke engine runs on a mixture of oil and gasoline, while the four-stroke engine burns
gasoline, making it similar to a car engine. In general, two-stroke engines are cheaper, quieter,
and smaller. They also have more torque. However, four-stroke engines the four-stroke engine
has an electric ignition switch and cleaner fuel consumption. The four-stroke engine also has a
good fuel economy and good acceleration.
Inboard engines are four-stroke automotive engines changed for marine use. They are
mounted inside the hull or in front of the rear of the boat. Inboard engines function by turning a
driveshaft that runs through the bottom of the hull and is also attached to the propeller on the
other side. The boats steering is controlled by a rudder which is located behind the propeller, and
a transmission that powers the boat. Inboard engines are more ideal as sporting boats because of
the fact that the propeller can be moved further back, allowing for easy access on and off the
back of the boat. There are two fuel options for inboard engines, gas and diesel. Diesel engines
are usually used on larger boats, but gas engines can have more horsepower, making them ideal

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for most types of boats. Gas engines also tend to be quieter, smaller, and have a simpler drive
system, but diesel engines have a longer life expectancy and can produce more torque.
I also learned about inboard engines, which is what this Volvo Penta facility specialized
in. Inboard boat engines work similarly to car engines in terms of how it creates power and
delivers drive to the boat. It is a combustible engine that has cylinders which fill with air and fuel
in the case of a gas or petrol inboard. Like normal combustion engines, a spark ignites this fuel
air mixture, creating an explosion. This combustion pushes a piston downwards; turning the shaft
it is connected to part way. The series of pistons pushing down at intervals causes the drive shaft
to spin. Inboard boat engines cannot push or move anything without something to push against
the water. Therefore, in most cases for inboards, the pushing is done by propellers that are
mounted under the boats hull. As the engine provides power, it distributes down a shaft via a
gear box or transmission. The shaft connects to the propellers and causes them to spin. The shaft
determines the speed of the propellers for this reason.
An inboard boat engine is cooled by water, but it doesnt use a common radiator. The
reason for that is because the inboard is surrounded by water so it is more efficient to use the
water for cooling, rather than to include a radiator. Water is pumped into the inboard engine from
the outside. There are various processes for this, including a hose or a hole in the stern where
water enters. All inboard boat engines use the water to cool the engine, and then push it back out
of the system with the exhaust from the engine, which is why water comes out of the back of an
inboard boat.
Much of my mentorship was spent working on hands-on experiences, and asking a lot of
questions. Mr. Stewarts job at Volvo Penta is to build prototypes and models from the engineers

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blueprints, and work on broken engines, whether it is to find the problem, or fix or replace the
broken/faulty part. Overall, the mentorship was very educational, realistic in the work
environment, hands-on, and encouraging. As a result of this mentorship, I learned most of the
parts of the boat engine, and the functions they each serve. This information is also applicable to
most combustion engines due to the fact that they are very closely related in parts and function.
In the future, I am more likely to major in the engineering field after this mentorship due to all
the hands-on experiences and positive interactions I saw during my time at Volvo Penta. After
many activities we did during the mentorship, I was often filled with questions and inquiries. I
was captivated by the work that the engineers at Volvo Penta do every day, and I could see
myself pursuing an engineering career.
Reflecting on my take-a-ways from this project, I am glad that I spend my time and effort
mentoring, making a product, and completing my paper. It has left me with a great sense of
satisfaction, and I cannot wait to present my project to my peers. I am leaving this senior project
fulfilling professional work experience, a sound base for marine engineering, and great pleasure
in having spent so much time looking into a field that fascinates me.

References

1.

Fluor. [Internet]. Glossary. [cited 2015 August 6]. Available from:

http://www.fluor.com/about_fluor/newsroom/pages/engineering_glossary.aspx

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2.

3.

Watersports. [Internet]. Different Types of Boat Engines. [cited 2015 July 27]. Available
from : http://watersports.answers.com/boating/different-types-of-boat-engines
Emil Hasl. [Interview]. [cited 2015 October 10].

4.

Steve Smith. [Internet]. How Do Inboard Boat Engines Work? [cited 2016 January 3].
Available from: http://www.ehow.com/how-does_5006306_inboard-boat-engines-work.html

5.

Steve Smith. [Internet]. How Do Outboard Boat Engines Work? [cited 2015 December
14]. Available from: http://www.ehow.com/how-does_5037952_outboard-boat-engineswork.html

6.

Steve Smith. [Internet]. How Do Outboard Motor Shifter And Throttle Controls Work?
[cited 2015 November 21]. Available from: http://www.ehow.com/howdoes_5006384_motor-shifter-throttle-controls-work.html

7.

Gabriel Hasl [Internet]. Discover More [cited 2015 December 11]. Available from:
http://discovermore.edublogs.org/