Heavy Duty Diesel & Gas Engine Rebuilding
It’s no light matter building large bore multiple cylinder engines. Engine builders believe there is only one right standard of workmanship. Fresh challenges surround today’s engine scene. Having an insight of the changes (particularly in the last 15 years) to fuel and crankcase oil chemistry, the use of low excise fuels and bio-fuels will assist and what influence they have on the longevity and overall performance of diesel engine life. Further changes include tighter working tolerances, ultra-high fuel injection pressures, higher combustion pressures/temperatures and tighter emission control laws are all part of the dynamics associated with the engine and rebuild industry.
The ‘hands on’ of engine building is a specialist field requiring a suitable skill set, expertise, experience, patience and engine knowhow for the particular engine being worked on. Ensuring the correct product for the application sets the tone for a good repair/rebuild. Adept engine builders insist on suitable and clean work space, correct tools, observation of the makers shop manual and upgrades. Attention to detail is mandatory when assessing castings/forgings and components for re-use. Condition and cleanliness of threaded bolt holes, torque settings and sequence (eg cylinder head bolt torqueing). Oil, water and/or fuel galleries thoroughly inspected, clear and clean. Accurate assessment of small parts and major castings eg. crack testing and deliberation of ‘use again’ components, replacement of worn and co-dependent parts, upgrading as necessary, machining as required to restore specifications, surface flatness and hardness (eg machined deck of cylinder block), correct assembly and set up procedures, start-up, run-in procedures and routine maintenance thereafter are all critical considerations for the best rebuild outcome.
Not one area of the engine or peripherals should escape assessment, overhaul or replacement. The engine assembly can be likened to a chain and the well-known adage ‘it’s as strong as the weakest link’. Any area overlooked, even if something was recently replaced should be considered an original part of the engine and requires the usual assessment and or replacement. Prior to and during assembly, thorough cleanliness and a dust/dirt free environment are most important. Inspection of the entire cooling system, lubricating circuit, fuel system, hosing, piping, clamping, air filtration (from air filter housing to engine), sensing devices, engine management systems and all recording sensors and harnesses are important to the sustainability of the newly built engine.