What you need from an engine overhaul

Regardless of whether you need an engine overhaul because of hours, time, or it is unplanned you need to know it is done right.

The first consideration is the content of the overhaul. Is it just a top-end, major overhaul, half-life or to rectify damage after a failure?

Next, is where the work is to be carried out? Ideally, this would be in a fully equipped workshop like ours, but sometimes this is not logistically possible or practical.

For site overhauls, swing engines or swing assemblies can be a great way to reduce timescales and costs.

When we are carrying out overhauls, they follow our 9 stage process, each one is outlined below:

1. Dismantle

The following SOP is followed during the engine dismantle stage:

  • Ensure the engine is drained of all fluids
  • If drained oil is available check for metallic residue
  • Mark the engine wiring harness
  • Remove Engine subassemblies (Turbocharger, Governor, Starter motor etc) and set aside
  • Remove engine from mountings and place on supporting frame or a turnover frame
  • Remove flywheel
  • Mark up alignment of free-end and driven-end gears
  • Remove front end and driven end gearwheels
  • Remove Exhaust and Intake manifolds
  • Remove coolant rails
  • Remove fuel pipes
  • Bar the engine over so the piston of the required cylinder is at TDC
  • Remove cylinder head covers
  • Remove rocker gear and injectors
  • Remove pushrods
  • Remove cylinder heads
  • Remove pistons and connecting rods
  • Remove cylinder liners
  • If possible, rotate the engine to give easy access to the crankshaft
  • Remove bottom of crankcase
  • Remove main bearing caps, crankshaft and camshaft

2. Clean

All items are thoroughly cleaned in our workshop by engineers manually, and using our ultrasonic cleaning, paint stripping and parts washing tanks and Guyson bead blaster.

3. Inspect

Each part of the assembly is inspected to ascertain if it is good condition, in need of replacement, machining or other work to bring it back to OEM specification.

4. Report & Approval

All workscopes we complete include a fully comprehensive report after stage one detailing our findings and recommended plan of action, along with cost and time implications.

Once we have your approval, we will progress the overhaul.

You will also receive updates as we progress through each stage.

This ensures you know exactly what stage we are working on, and have the peace of mind that all steps have been documented for your reference.

5. Replace

Where a replacement is the only option for any of your components, we can source directly from OEM and component manufacturers.

As an established business we have direct links to OEM and original component manufacturers and can offer fast turnaround times at great prices.

We are also dealers for MTU, Baudouin and Bosch, so can guarantee preferred rates and lead-times.

6. Refurbish

With our in-house manufacturing and machining capabilities, we are able to offer alternative solutions rather than just replace.

All these repairs would be covered by a 12-month warranty and comply with OEM specifications or industry standards.

This can provide a more cost-effective and quicker option than replacements.

7. Build

The following SOP is followed during the engine rebuild stage:

  • Install camshaft and check end float
  • Fit crankshaft and place Plastigauges on crankshaft main journals
  • Install new main bearing shells, and torque to OEM spec. Ensuring bearing shells match up with crankcase.
  • Remove bearing caps and inspect Plastigauges
  • Lubricate crankshaft & bearings and torque to OEM spec.
  • Measure end float and check free rotation of the crankshaft
  • Fit bottom of crankcase/sump to engine
  • Fit front end and driven end gearwheels
  • Rotate engine to insert cylinder liners
  • Check liners for ovality to ensure fitted correctly
  • Pressure test crankcase
  • Insert pistons and connecting rods
  • Mark connecting rod ends when torqued up
  • Fit cylinder heads with new gaskets
  • Bolt down cylinder heads, increasing torque setting in stages up to OEM spec. (ie torque all bolts to 1/3 OEM value, then 2/3, then 100%)
  • Check the bumping clearance of each cylinder
  • Fit rocker gear and injectors
  • Fit cylinder head covers
  • Fit inlet and exhaust manifolds
  • Fit coolant and oil lines
  • Fit fuel lines
  • Fit flywheel
  • Fit engine subassemblies (Turbocharger, Governor, Starter motor etc)
  • Final Assembly
  • Fill engine with fluids and check for leaks
  • Rotate crankshaft two full rotations
  • Fit engine guards

8. Test

On completion of the overhaul, the engine will be tested against an agreed test plan and can be witnessed by you, a representative or live streamed.

Once accepted, the engine can be packaged and shipped back to the site or stored in our warehouse, ready when needed.

Our engineers can then attend to re-install and commission, checking alignments and test running on site.

9. Final Report

On completion of the overhaul, a full report including all stages will be provided, along with our 12-month warranty as standard.

For an example of an overhaul report, click here.

If your engine is in need of an overhaul that you can count on, fill in your details below – we’d be happy to Help.

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