This work scope involved the full overhaul and dyno test of a client’s Dorman 6LDT Short Block Engine.
To illustrate the thorough service Bartech provide, we’d like to give you an insight as to what our standard reporting protocol for works carried out looks like, please see the following excerpts from engineers reports. Do note that there have been five separate reports sent to the customer and this is a breakdown of all five.
Following the receipt of the base engine, below is an update on progress so far:
The electrics have been disconnected from the engine and from the alternator.
The turbos and air filters were removed in order for the engine to be removed from the skid and the container. (figure 1 & 2).
The engine was then lifted into the workshop for inspection (figure 3).
The engine spill timing was checked and engine components were marked for aiding reassembly after overhaul. The spill timing was within specification.
The following items have been removed from the engine for inspection and overhaul as required: (figure 4):
The plan is to continue with the dismantling of the engine, carry out an inspection, clean and rebuild the engine.
During the overhaul and rebuild the following will be replaced with all new parts:
The engine has been completely dismantled down to a bare crankcase.
The following components have been measured and inspected;
The crankcase has been cleaned in preparation for rebuild.
All engine components following dismantle were sent for chemical cleaning. Upon return, some items required bead blasting before a visual inspection could be conducted to review any potential areas of concern of damage. None was evident.
In addition the following has been conducted:-
Some heavily corroded bolts and studs sheared when removing engine components. These required machining and re-tapping (Figure 5). These included:-
Quantity two e bores are partially corroded and will require re-machining or suitable repair under taken.
Plan for next week:-
We have repaired the damaged e bore highlighted last week using Belzona (figures 1-5). It was not necessary to repair the second e bore.
We have drilled out broken and damaged studs and repaired the threads on the Turbocharger (figure 6)
Drilled out the corroded and seized bolts on the exhaust elbow (figure 7)
Drilled out broken and damaged studs and repaired the threads on the exhaust manifold (figures 8 & 9)
Cylinder head valves and valve seats have been cut, cleaned, lapped (figure 10) and vacuum tested (figure 11) to insure correct sealing.
The liners required cleaning and painting and are now ready for fitting.
The crankcase has been re-cleaned following the e bore repairs.
Pistons have been fitted to connecting rods.
The liners have been fitted and the crankcase pressure tested to 60psi for 1 hour. No leaks have been identified.
The crankshaft has been fitted.
It was not possible to check the end float of the crankshaft to confirm within manufacturers tolerances as the tab washers were damaged and require replacing. These are expected to arrive today so this activity can be completed.
We have re-fitted x2 injector tubes and core plugs on both cylinder heads and we have pressure tested to 60 psi for one hour and there were no issues of note.
The oil cooler has been disassembled, cleaned and is being rebuilt. New seals will be fitted. One of the valves will require lapping before assembly to guarantee a complete seal.
Plan for next week:-
The damper and water pump will be replaced.
Additional work carried out:
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