Diesel Depot

Remanufacturing a Cummins 4BT Diesel engine involves many critical steps. Below you'll see the engine components and how we handle each of these in our remanufacturing process. Think of them as our steps towards producing a top quality replacement engine.

Engine Block/Case

The rebuilding process starts with the bare cylinder block/case. The bare block is examined carefully to determine whether or not it is suitable for rebuilding. Checking For... Internal Cracks External Cracks Cylinder Wall Cracks Deck Surface Cracks Cam Bore Case Size Crank Bore Case Size Cylinder Bore Size Damaged Threads Machine Work Performed... Bore Cyl. Max .040" Precision Hone Cyl. Sleve as Required Resurface Block Deck Head Bolt Holes Tapped Finish Work On Block... Thorough Cleaning Case Plugs Installed New Water Jacket Plugs Fasteners Cleaned Painted To Color

Crankshaft
	The crankshaft is one of the primary components of the engine's internal rotating assembly. Checking For... Rod Journal Size Main Journal Size Crank Straightness Fasteners Threads Physical Damage Machine Work Performed... Polish Rod Journals Polish Main Journals Renew Woodruff Keys Turn Rod Journals Turn Main Journals Turned .010, .020, .030

Camshaft & Lifters
	The camshaft and lifters are also serviced as part of the rebuilding process. Remanufactured lifters are installed along with a quality inspected used camshaft. Checking For... Cam Bearing Diameter Cam Lobe Sizes Physical Damage Block Lifter Bores Check Cam Gear Only Used If STD Size Machine Work Performed... Polish Bearing Journals Polish Lobes Renew Woodruff Keys Reman Lifter Inspection

Rockers & Pushrods
	Other valve-train components are the rocker arm assemblies and pushrods. Checking For... Rocker Stem Wear Rocker Socket Wear Rocker Retainers Rocker Shaft Condition Pushrod Ball Wear Pushrod Straightness Machine Work Performed... Thourally Clean

Connecting Rods
	The connecting rods are taken through an extensive remanufacturing process. Machine Work Performed... Matching Rod Lengths. New Wrist Pin Bushings Shot "Peened"

Cylinder Heads

The cylinder heads are an important component of any engine; they function as the "lungs" of the engine. They are critical to the performance and life of our engines, so our engines always receive a top quality remanufactured cylinder head. Checking For... Cylinder Face Cracks Valve Seat Cracks Valve Bowl Cracks Valve & Seat Wear Valve Springs Guide Clearance Valve Condition Rotators & Cups Head Straightness Fastener Threads Overall Head Thickness Machine Work Performed... Reface Valves Reface Valve Seats Replace Seats as nec. Set Valve Recession Set Valve Stem Length Head Surface Trued Stem Guides Replaced 3-Angle Valve Grind

Bolt On Items
	Many items are cleaned, inspected, and re-used within our remanufactured engines. These parts are listed below. Components Inspected... Oil Pan Timing Cover Harmonic Balancer Valve Covers Other Build-2-Order Items

New Internals

Below you'll see the components that are replaced with new parts in every remanufactured engine. Pistons MAHLE .020, .030, .040 Max STD Compression OR .010" Topped W/ New Pin Retainers W/ New Wrist Pin W/ Annodized Crown W/ Coated Skirts Piston Rings MAHLE .020, .030, .040 Max Proper End-Gap 2-Piece Oil Ring Engine Bearings KING Or Clevite 77 STD or OS Rod STD or OS Main Standard Cam Bearing Misc. Components Wrist Pin Bushings Threaded Block Plugs Block Soft Plugs Head Valve locks Gaskets & Seals Felpro Head Gaskets STD Head Gaskets +.010 Front Main Seal Rear Main Seal 1-p

Engine Assembly

After the final machining processes are completed and the components to be used in the engine are inspected, the engine is assembled. During this assembly process critical specifications are checked and re-checked to make sure the completed engine is up to our high standard of performance. Items Verified... Main Bearing Clearance Rod Bearing Clearance Cam Bearing Clearance Camshaft endplay Crankshaft endplay Install KDP Plate Piston Ring Endgap Piston Height

	Upgrades & Options
Beyond the OEM oriented rebuild offered above there are several upgrades and options also available. These are geared at either improving durability or improving power output, and in many cases both.

Balancing

A balanced rotating assembly is a highly recommended upgrade for any engine. Our procedure utilizes a Multi-Bal 3000 computerized engine balancer. Using this equipement we are able to take our rotating assemblies down to what are widely considered race engine tolerances. Benefits... Smoother Running Reduced Crank Fatigue Longer Crank Life Reduced Internal Wear Increased Power In Order to complete the balancing process a majority of the engine's rotating assembly components must be modified. Components Modified... Match Piston Weight Match Rod Weight Modify Crank Throws

Cyl. Head Porting

Cylinder head porting and gasket matching is a way to improving power output of the 4BT. Removing unnecessary material from the exhaust ports of the cylinder head helps improve airflow into and out of the engine. Thus, the potential for increased power is improved. Depending on the customers desires a gasket/port match, port blend, or full porting may be peformed. Benefits... Increased Power Lower EGT's Less Black Smoke Better Fuel Economy

Lower Compression Ratio

Lowering the compression ratio of a 4BT is a way to increasing durability while running the engine at higher than designed power and boost levels. There are several ways to lower compression. We typically reduce piston height or use of aftermarket pistons where available. Benefits... Safer At High Power Increase HP Potential Increase TQ Potential Allows For More Boost Allows For More Fuel Best Head Gasket Life Less Block Stress Less Crank Stress Decreased Wear

ARP Head Studs
	ARP's head studs provide greater clamping force between the block and the cylinder head and are a performance oriented upgrade. The studs replace the factory head bolts. They are recommended for higher boost level engines. Benefits... Less Gasket Failure Better Clamping Stronger Re-usable

Ceramic Coatings

High temperature ceramic coatings can be applied to a number of internal and external engine components. The coatings are designed to either reflect heat away from or to trap heat inside the parts on which they are applied. The use of these coating can greatly improve the overall thermal efficiency of an engine and parts. Items To Protect and Coat... Piston Crowns Head Exhaust Ports Head Exhaust Bowls Head Chamber Intake Valves Exhaust Valves Exhaust Manifold Exhaust Manifold Ports Most of the uses of ceramics are for the protection of the engine components to help them resist the heat that can destroy them. In some instances, ceramics can also be applied to protect external components such as exhaust manifolds and headers against rust, and insulate heat away from the engine. Benefits... Heat Rejection Increased Engine Life Less Part Cracking Less Coolant Temp Increased Component Life

Gapless Piston Rings
	Using gapless piston rings by Total Seal Inc. reduces blow-by by giving a supperior ring seal. This upgrade utilizes Total Seal's gapless 2nd ring and Mahle's top compression ring & oil control ring. Benefits... Less Blow-By Cleaner Engine Oil More Compression More Power

Fluidampnr Balancer
	Upgrading the factory balancer to the Fluiddampr balancer reduces vibration across the engines entire RPM range. Benefits... Safe Engine Harmonics Smoother Running Reduced Vibrations Slight Power Increase mproved Crank Life