Each of our ‘donor’ engines is completely dismantled and thoroughly cleaned using an ultra high-pressure and environmentally friendly wash system, then each component receives individual treatment as follows :
Camshafts are either replaced with a new unit, or re-profiled to their original specifications.
Cylinder Heads are thoroughly cleaned using an ultra high-pressure and environmentally friendly wash system. The heads are checked for distortion and thickness then inspected for cracks and the camshaft bores measured for size, shape and alignment. The valves are examined for damage, head thickness, and stem wear then replaced as necessary; valve guides are measured for wear and replaced as required; valve seats are machined to the correct angles, widths, heights and seating concentric to the centre line of the valve guide bore; and valve springs are checked for extended and compressed height and compressed load length. When each head is machined, particular attention is paid to maintaining the correct surface finish specified by the gasket manufacturer.
Crankshafts are micro polished after grinding to achieve the exact dimensions and surface finish required; diesel cranks are crack tested; sealing diameters and nose ends are measured and reclaimed if necessary; blended radii, thrust wear and alignment are checked; and all oil galleries are de-burred and thoroughly cleaned.
Cylinder Blocks are re-bored or re-sleeved, and honed to regain the precise surface finish and cross-hatch; main housings are measured for size, roundness and alignment, and machined as required.
Connecting Rods are checked for alignment and then weight-graded into engine sets; housings are measured for size, round and taper, and machined as required, small-end bushes are renewed.
Oil Pump pressure relief valves are dismantled and cleaned; the clearance between the rotor and body is measured; and all worn/broken parts are replaced.
|Replacement Components are of equal to or higher specification than parts fitted by the original manufacturers.All engines are fitted with new pistons, gudgeon pins, piston rings, main and big end bearings, small-end bushes, timing chains, gaskets, oil seals & core plugs.Fitting a Replacement Engine?Learn from other peoples mistakes rather than your own. Here at Auto Services Doncaster Ltdwe have witnessed some monumental bloopers that are difficult to believe, they are all related to engines or vehicles that have been fitted by the customer or his mechanic.They do happen and we have photos to show what can go wrong if basic checks and simple tasks are not carried out prior to engine fit.Every reconditioned engine that leaves our workshop is accompanied by a short set of basic fitting Instructions giving a few do’s and don’ts for the person fitting the engine.Below is a list of all the problems we have come across:|