Remanufacturing a GM diesel engine involves many critical steps. Below you'll see the individual components of the engine and how we process each component during our remanufacturing process. Think of these as our steps for producing a top quality replacement engine.
| Engine Block/Case |
|
||||||||||||||||||
|
The rebuilding process starts at the bare cylinder block/case. Every engine is stripped down to the bare block casting which is examined carefully to determine whether or not it will be suitable for rebuilding.
|
||||||||||||||||||
| Crankshaft |
|
||||||||||||
|
The Crankshaft of any engine is a primary component of the engine's internal rotating assembly. Currently, only standard diameter crankshafts are being used due to the risk of weakening the crankshaft during resizing of the rod and main journals.
|
||||||||||||
| Camshaft & Lifters |
|
||||||||||||
 
|
The camshaft and valve lifters are also serviced as part of the rebuilding process. Remanufactured lifters and a quality inspected used roller camshaft is installed.
|
||||||||||||
| Rockers & Pushrods |
|
||||||||||||
 
|
Along with the cam and lifters, the other components of the valve-train are the rocker arm assemblies and the pushrods.
|
||||||||||||
| Connecting Rods |
|
||||||
|
The connecting rods of the engines go through an extensive remanufacturing process.
|
||||||
| 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.
|
||||||||||||
| Bolt On Items |
|
||||||
|
Many parts are inspected and re-used within our remanufactured engines. These parts are listed below.
|
||||||
| New Internals |
|
||||||||||||||||||||||||||||||||||||
  
|
Below you'll see the critical components that are replaced with new parts in every remanufactured engine that we sell.
|
||||||||||||||||||||||||||||||||||||
| 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.
|
||||||
|
|
Upgrades & Options |
|
|
Beyond the OEM oriented rebuilds, there are several upgrades and options available to make our engines even better. The upgrades and options offered below are geared at either improving the overall durability of the engine or to improve power output, and in many cases both. Diesel Depot offers more upgrades and options than any other rebuilder that specializes in the 6.5L GM diesel engine! |
||
| Balancing |
|
||||||||||||
|
A balanced rotating assembly is a highly recommended upgrade for any engine, and the GM diesels certainly benefit greatly from this premium procedure. Our balancing operations are performed on a Multi-Bal 3000 computerized engine balancer. Using this equipment we are able to take our rotating assemblies down to what are widely considered race engine tolerances.
To complete the balancing process a majority of the engine's rotating assembly components must be modified.
With every balanced assembly a new harmonic balancer and a new flexplate is included. The GM Diesels are externally balanced so it is critical that these bolt-on items are as good as possible. Customers may also supply their own good flexplate or flywheel to be used during this process. |
||||||||||||
| Cyl. Head Porting |
|
||||||
|
Cylinder head porting and gasket matching can be an added to improve power output of the GM diesels. Removing unnecessary material from both the intake and exhaust ports of the cylinder heads helps airflow into and out of the engine. By increasing air volume through the engine, the overall potential for increased power output is improved. Depending on the customer’s desires a gasket/port match, port blend, or full porting is available.
* The intake manifold and exhaust manifolds can also be modified to complete this upgrade. |
||||||
| Lower Compression Ratio |
|
||||||||||||
|
Lowering the compression ratio of the GM diesels is a way to increase durability of the engine if the engine is to be run at higher than stock power and boost levels. There are several different ways to lower the compression ratio. We can use a combination of these methods to get to a customers desired level. The most commonly used method is a lower piston height in the cylinder. The only disadvantage of this modification is harder cold starting in certain environments. This can be overcome with the addition of intake air heaters, quick heat glow plugs, or extended glow and afterglow times.
*The 18:1 and 18.5:1 Compression ratios are the common accepted "marine" lowered compression ratio. Please ask for advice about other compression ratios if they are desired. |
||||||||||||
| 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 Torque-to-Yield (TTY) head bolts.
|
||||||
| 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.
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.
|
||||||||||||
| Bal. Rocker Arms |
|
||||||
|
|
Balancing rocker arms for the GM diesels involves a proprietary technique developed by Diesel Depot. We selectively pick our best rocker arms and group them together in balanced sets of 16. These balanced sets are all within the tightest tolerance possible. The rocker assemblies are then built using new GM nylon rocker arm retainers on a freshly polished rocker arm shaft.
* Pushrods can also be precisely measured for length to complete the matched set. |
||||||
| Gapless Piston Rings |
|
||||||
|
By using gapless piston rings from Total Seal Inc., engine blow-by can be greatly reduced. This upgrade utilizes a gapless 2nd compression ring and uses Mahle's top compression ring and superior 2-piece oil control ring.
|
||||||
| Stud Girdle |
|
||||||
  
|
The Stud Girdle is an upgrade that improves the stability of the lower rotating assembly in a GM diesel engine. The "kit" contains a set of outer main cap studs as well as a compact girdle to reinforce the center main caps and block webbing. This upgrade improves the durability of any GM diesel block, and should be considered for any engine rebuild, whether you are looking for increased power or fuel economy.
|
||||||
| Dual Idler Timing Gears |
|
||||||
|
The dual-idler timing set is an upgrade that offers both improved durability and performance for the GM diesel engines. The stock timing chain, which stretches over time, is replaced with a timing gear set that offers accurate valve-train and injection pump timing for the life of the engine. This increased durability and consistency of the gear set also helps maintain more stable power output and efficiency for the life of the engine.
|
||||||
| Oil Cooler Line Size |
|
||||||
 
|
The Oil Cooler lines used on 6.5L engines prior to 1997 year model used 3/8" NPT sized fittings. Due to core block availability the earlier, and in many cases stronger, pre '97 block can be substituted in place of the later block. We increase the diameter of the oil cooler ports from 3/8" to 1/2" NPT so the earlier blocks can be used without adapters. This is an upgrade option if the earlier "599", "929" or "141" block casting is desired over the later "506" casting.
|
||||||
| Fluidampr Balancer |
|
||||||
|
New for the 6.5L is the Fluidampr replacement harmonic balancer. This upgrade is considered both a performance and a durability improvement. Diesel Depot is also proud to announce that we assisted Fluidampr in the development of the product for the 6.5L. We are very excited about this upgrade.
|
||||||
| Scat Crankshaft |
|
||||||
|
|
New for the 6.5L is Scat's improved crankshaft design over the factory GM crankshaft. The Scat 9000 Series crankshaft can be used in 6.5L rebuilds and can be used in conjunction with our balancing option to create a stronger rotating assembly.
|
||||||
| Beyond The Long-block |
|
||||||
Beyond building a better long-block engine we also offer bolt-on accessories and upgrades. These are external items that you may need along with your new long-block. We can go as far as installing all external components to make our engines full drop-in replacements or to make our engines complete for conversion applications.
|
|||||||