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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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