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| ENGINE BLOCK REMANUFACTURING |
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| STEP 1) ENGINE BLOCK DISASSEMBLY |
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Dirty Engine Block
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All blocks are visually inspected for
casting defects prior to their disassembly
and the beginning of engine block
remanufacturing. The parts are then
removed and individually inspected for
damage and cause of failure. The oil and
water passage plugs are removed to insure
optimum results during the thermal cleaning
process.
Only premium castings are used for our
marine blocks, all castings are replaced in
all salt-water applications. Our high
performance engines are built with premium
cores. In many applications new castings are
used, as we never employ repaired castings
or sleeved blocks. To retain your classic
car's original block casting, Promar employs
the artistry of our skilled casting repair
technicians.
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| STEP 2) ENGINE BLOCK THERMAL CLEANING |
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Oven-Cleaned Engine Block |
The thermal cleaning system gives our
customers the closest thing to a new
casting, taking engine parts to a whole new
level of clean. The heaters emit uniformly
controlled heat, which is evenly distributed
throughout the chamber. This method totally
eliminates the concentration of intense heat
or flame entering the chamber, which could
overheat, warp or melt parts. The load is
heated to 650-800 F (340-427C) in an oxygen
deficient atmosphere, where the combustible
hydrocarbons decompose and parts leave the
oven completely dry. This baking process
used on cast iron blocks only employs the
Ace RKE 230 oven. Ash residue is easily
removed by stainless steel shot blasting
which is the next step of our engine
restoration services.
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| STEP 3) ENGINE BLOCK SHOT BLASTING |
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Engine Block After Shot Blasting |
Our shot-blasting machine employs a cleaning
method using stainless steel shot. This
finishing process is used by Promar to
remove surface contamination such as rust
and irregularities from engine blocks during
remanufacturing. The result of this method
is a cleaner smoother surface finish to make
easy the detection of surface and subsurface
casting defects during quality inspection.
To insure stress free casting, the
peening process is used to impart
compression strength to metal parts. This is
accomplished by metal shot pellets acting
like miniature ball peen hammers as they
strike the entire surface of the block. All
iron castings are put through this process
before a preliminary inspection for defects
is done. This process using the AR HB41 is
employed for cast iron blocks only and
facilitates a more accurate magnetic
particle inspection.
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| STEP 4) ENGINE BLOCK MAGNAFLUXING |
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Engine Block Crack Detection |
Magnetic particle inspection is the most
definitive method of detecting cracks and
imperfections in any ferrous engine parts.
This procedure, as part of our engine
restoration services, assures the highest
quality cast iron blocks. The next process
is pressure testing, but first, let us
explain how aluminum blocks are cleaned,
pressure tested and checked for casting
defects.
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| STEP 5) ENGINE BLOCK HIGH PRESSURE WASH |
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AXE SW20 OS Spray Cleaning System |
The first stop for a qualified aluminum
engine block during
remanufacturing is our AXE SW20 OS spray
cleaning system. With twice the spraying
power and a dramatically increased number of
multi integrated spray nozzles, this state
of the art system assures Promar that all
oil, dirt and foreign material is removed
from even the smallest of oiling holes.
Cleanliness of the aluminum engine block is
essential to insure an accurate inspection.
This process is used on all aluminum engine
blocks as a first step prior to the second
step of ultrasonic cleaning.
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| STEP 6) ENGINE BLOCK SONIC CLEANING |
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GMC 1818B Ultra Sonic Cleaner |
Promar's second process in the cleaning of
aluminum blocks is the ultrasonic cleaning
method, long known as the "benchmark" in
cleaning and
engine restoration services. Hundreds of
specifications reference an ultrasonically
cleaned part as the ultimate target for
cleanliness. Ultrasonic cavitation is able
to clean right down to the surface of a part
and beyond. It is also able to reach
internal areas, which are not accessible by
using other cleaning means including spray
and mechanical agitation. The forceful
nature of ultrasonic energy provides the
physical "push" required to break the
mechanical and ionic bonds that hold very
small particles to surfaces. Once cleaned
the block is sent for pressure testing.
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| STEP 7) ENGINE BLOCK PRESSURE TESTING |
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Delta 6000 Pressure Tester Machine |
Promar uses the Delta Pressure tester to
double check for pin holes after
magnafluxing and dye testing are completed.
Cracks and defects not detected during the
first process are found at this time. This
second process insures the integrity of all
castings used in Promar products.
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| STEP 8) ENGINE BLOCK PREPARATION |
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Engine Block Preparation |
A complete visual inspection of the block is
performed. Repairs will be made to minor
casting defects, removal of broken bolts are
performed as well as repair and tapping of
threads. Gasket surface repairs are
performed to minimize stock removal. The
next step of
engine block remanufacturing is align
honing.
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| STEP 9) ENGINE BLOCK ALIGN HONE |
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Engine Block Align Honing Process |
Align honing is the best method for
precision alignment of main bearing bores.
Promar uses the Sunnen CH-100 machine for
all of its benefits and features, as we can
minimize stock removal, usually less than
.003" (.076 mm) off the caps compared to as
much as .010" (.254 mm) with boring.
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Use of this machine maximizes precision and
corrects distortion caused by warpage and cap
stretch. This align hone procedure exceeds
original factory accuracy for alignment,
roundness and size and precedes the engine
boring process.
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| STEP 10) ENGINE BLOCK BORING |
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Rottler F54X Boring Bar |
Promar employs the Rottler F54X boring bar
with its large diameter and hard chromed
spindle. This spindle is supported on
adjustable tapered bearings for superior
accuracy. The F54X uses a precision ground
ball screw to control feed rate and cutter
position. By controlling these factors the
machine can repeat cutter position accuracy
to .0002" (.005mm). With its digital
programmable cycles, the F54X allows boring
depth to be programmed to .0001" (.0025mm).
The next process of our
engine restoration services to follow
boring is milling.
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Engine Block Boring Process
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| STEP 11) ENGINE BLOCK MILLING |
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Milling machines that are used by Promar are set
up specifically for blocks. The Winona Van
Norman M3000 machines are used for their
variable feed rate, which is essential to
acquire proper Ra finish for each block. Ra
finish determination is based on the type of
block, be it aluminum or cast iron, and by the
type of gasket used for each specific
application. These machines utilize CBN (cubic
boron nitride) cutters, which are second in
hardness only to a diamond. During the cutting
process heat from friction is absorbed and
carried off by the discarded metal chips thus
resulting in improved accuracy and excellent
surface finish. The surface finish is then
checked by using the Mitutoyo SJ-301. The
Mitutoyo SJ-301 is utilized twice, once after
resurfacing and again before final assembly
Promar insures proper measurement of Ra by using
the SJ-301. The next process of
engine block remanufacturing is rod
reconditioning.
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M3000 |
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Engine Block after Milling Process |
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| STEP 12) ENGINE BLOCK ROD RECONDITIONING |
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Sunnen LBB-1600 |
The ideal equipment for precision rod
reconditioning and pin fitting is the Sunnen
LBB-1600 Hone, which measures accuracy
within .0001". This hone method is preferred
all over the world for its ability to
produce a round and straight honed bore
equal to or better than the manufacturer's
new rods.
All high performance engines are fitted
with ARP high strength bolts and nuts prior
to rod reconditioning. Once reconditioning
of the rods is accomplished the next step of
engine restoration is honing of the
cylinders.
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Connecting Rod Bore Checking Process |
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| STEP 13) ENGINE BLOCK HONING |
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The cylinder honing process assures precision
sizing plus exact Ra finish in every cylinder in
any type block. Promar finds that the automatic
Sunnen CV-616 Cylinder Hone ensures better than
original factory accuracy and corrects taper and
out-of-round. Another benefit is that it
produces surface finish, size, roundness and
straightness tolerances equal to or better than
original manufacturer's specs. The CV-616
produces consistent precision surface finish
with uniform crosshatch pattern in each
cylinder.
CV-616 provides base metal finish, free from
fractured metal for immediate ring seating and
positive oil control. It works for passenger
cars, high performance engines, trucks, diesel
and industrial blocks. This precision machinery
hones any material including aluminum, cast iron
and any alloy.
Promar insures proper measurement of Ra by
utilizing the Mitutoyo SJ-301 twice, once after
honing and again before final assembly. Final
assembly and completion of
engine block remanufacturing is not started
until all blocks go through a final wash.
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Sunnen CV-616 Engine Block Honing Machine |
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Engine Block Honing Process |
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| STEP 14) ENGINE BLOCK HIGH PRESSURE WASH |
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AXE SW 20-OS |
Following these precise machining procedures
and
engine restoration services, our blocks
undergo a second high pressure wash cycle to
guarantee the removal of any debris that may
have adhered or become dislodged during the
machining process. Absolute cleanliness is
necessary for the next step, which is final
assembly. After the blocks receive a final
wash we clean all parts ultrasonically.
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| STEP 15) ENGINE BLOCK SONIC CLEANING |
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GMC-1818B Ultra Sonic Cleaner
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Promar's second process is ultra sonic
cleaning of all parts old and new prior to
assembly of the engine. This Ultrasonic
Cleaning Method is long known as the
"benchmark" in cleaning. Hundreds of
specifications reference an ultrasonically
cleaned part as the ultimate target for
cleanliness. Ultrasonic cavitation is able
to clean right down to the surface of a part
and beyond. It is also able to reach
internal areas, which are not accessible by
using other cleaning means including spray
and mechanical agitation. The forceful
nature of ultrasonic energy provides the
physical "push" required to break the
mechanical and ionic bonds that hold very
small particles to surfaces. Once the parts
are cleaned, they are now ready to be
assembled in our Promar engine.
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| STEP 16) ENGINE BLOCK ASSEMBLY |
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At Promar there are no assembly lines during
engine block remanufacturing. All engines
are custom built. Each assembler does a visual
inspection of the block, heads, crankshaft and
all-inclusive parts prior to assembly. The Ra
tester is used to check all cylinder bores,
crankshaft journals and gasket surfaces. All
parts such as crankshafts, bearings, cylinder
bores, pistons, rings, connection rods, main
saddles, lifter and camshaft bores are miced for
proper size.
Each block is fitted with new full circle cam
bearings, oil restrictors, relief valves, new
water and oil plugs. The crankshaft is fitted in
the block with new high quality bearings and
each journal clearance is checked with
plastigage, torqued and double-checked. New
rings are then fitted in each bore to assure
proper end gap. Each new piston is checked for
proper clearance in each bore. The rings are
installed on the piston and assembled into the
bores. Each assembly is supplied with new high
quality bearings and each journal clearance is
checked with plastigage, torqued and
double-checked. A new camshaft is then fitted
into cam bearings bores and all new timing
components are installed and double-checked by
an assembly manager.
Cylinder heads are then installed with new head
bolts and new Felpro or Victor head gaskets. The
block now receives new lifters, push rods and
rocker arms which are adjusted and a second
check completed by an assembly manager. Each
cylinder is then accurately checked for seal
integrity to assure no compression or water
leaks. At this point the engine is primed with
special lubricant and a new oil pump. The
residual parts of the gasket set are sent along
with the engine. The assembly manager then
conducts the final inspection of the engine.
All engines come with an installation manual.
Bulletins about your specific engine are also
enclosed in the packaging. Promar engines are
secured onto a wooden pallet where vulnerable
parts are protected from damage by corner
covers. The entire block is wrapped in a durable
plastic sheath to protect your engine from
outside elements.
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Engine Block Check |
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Engine Block with Crankshaft Installed |
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Engine Block with Cylinder Head Installed |
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Completed & Wrapped Engine Block |
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