Our process is designed to not only make the top quality “better-than-new” engines, but to make the process repeatable so every single engine we produce is that same top quality every time. We have invested hundreds of thousands of dollars in the latest equipment including high powdered washed and ovens for cleaning, CNC machines for precise machining, and smart tools for assembly.
Comparing our engines to the “competition” really isn’t much of a competition at all. Our proven process allows us to produce thousands of engines each year, each of which incorporate the latest updates for “better-than-new” quality.
Research and Development
Before we offer a new product our highly trained experts research how to make the engine better-than-new. We start by thoroughly studying cataloging resources to ensure your new engine fits perfectly in place of your worn out engine. Next, we use our vast database of Original Equipment and aftermarket service bulletins and advisories to find the most common design flaws in the engine so we can correct them.
We start the build process by identifying the core engine to be correct for the part to be built. Casting numbers for the cylinder block, cylinder heads, crankshaft and other raw materials are inspected to ensure 100% accuracy. The core processing team uses the information provided by the research team to identify components specific to each part number.
Core engines are visually inspected before the build process is even started. This saves time (and money for you) by not proceeding with a raw material that will not meet our stringent qualifications.
Correctly inventorying and cataloging reclaimed engine parts is crucial. Our disassembly team carefully takes apart core engines to be sure no parts are damaged during the process. Next, they fasten a tag to each part to be reclaimed so that it stays with the same core engine as a whole. Parts which are not reused such as pistons, rings, broken connecting rods, etc. are all recycled.
Cleaning and Prep
Components to be reused are then cleaned using a variety of treatment processes. We start by slowly baking the components in a massive oven to loosen the crusty dirt/debris. Next the parts go into high powered washes which clean them from a wide variety of different angles to get into every crack of the raw material. Many components are shot blasted to provide a like new finish. Unlike many competitors we use soda to blast parts instead of glass beads. Glass beads can get stuck inside of the engine which will recycle into your new engine, while soda becomes a soluble powder which dissolves.
Once the reusable components are prepped they undergo preliminary testing to qualify them as suitable for using for remanufacturing. During this stage blocks and cylinder heads are magnafluxed and pressure checked to find any cracks or defects in the raw materials. A second inspection of the raw materials is performed where many components are discarded for cosmetic or mechanical defects.
Perhaps our favorite portion of the build (I know it’s weird but hey, we’re gearheads) is machining. This is where our technology outshines the competition and separates a Factory Direct engine from the smaller rebuilders who haven’t invested the money and research. The machining phase is also where we really start incorporating updates from our extensive research to make a better-than-new engine.
Cylinder blocks are machined through several different processes. First we bore the cylinder to a predetermined oversize. Next the bores are diamond honed to bring the cylinder to a precise size and finish. These processes are crucial to have correct compression and oil control inside of the cylinder. Next, the surface of every block is decked for a tight seal against the cylinder head surface. Later on in the assembly portion of the build, aftermarket pistons account for the slight change in compression height to avoid changing the compression ratio of the engine which can cause excessive heat and detonation. Lastly, blocks are align honed to provide exact fitting for the rotating assembly to increase engine life.
Cylinder heads are completely remachined prior to assembly as well. Valve seats are at least three-angle machined, many times five or seven angle machined (depending on the part) to provide reliable flow and sealing. In many applications we use nitrided valves which are far superior to alternatives. Valve stem height and valve lash are measured to an exact specification. New high-temperature valve stem seals are installed for optimum sealing and improved oil control.
Every crankshaft is reground to specific tolerances. Our crankshafts are micro-polished on a specialized machine to extend bearing life. Micro-polishing provides a superior finish on the crankshaft journals that other builders can’t replicate by simply grinding the crankshaft.
Both ends of the connecting rods are remachined to better-than-new tolerances. Just like cylinder blocks, connecting rods are diamond for a precise size and surface finish. Unlike many other remanufacturers, any rods which are bent or out of alignment are recycled and not bent back into place. Our processes optimize bearing life to extend the longevity of the engine.
Once machining is completed, each component undergoes a final wash prior to assembly. Similar to first wash, the final wash utilizes high pressure jets from multiple angles to thoroughly clean every crack in the engine.
Our assembly process revolves around documented quality control procedures for a consistently repeatable quality product. Many smaller rebuilders use inferior, outdated technology for engine assembly or, even worse, assemble engines by memory. To minimize delays and provide the highest quality, many parts used during assembly are Original Equipment grade or better.
Many stations on our assembly line feature tools with advanced technology to remove human error. These tools automatically assign and initiate proper the proper torque and sequence by scanning the barcode of the SKU which essentially eliminates human mistakes. Tools are recalibrated on a specific schedule to ensure any changes are implemented and they are functioning properly. These tools are another example of a huge investment to provide the highest quality product other builders can’t, or won’t, match.
Testing and Quality Assurance
Prior to packaging, every engine assembly is fully tested using a simulation test machine. Our highly skilled engine experts rotate the engine at a variety of RPM ranges to verify all engine parameters are to specification including compression, oil pressure, flow, abnormal noises, vibration, and valvetrain functionality. Every engine has a specialized oil dye installed during testing and is thoroughly inspected with a black light to find any fluid leaks. On many engines which use variable valve timing (VVT), active fuel management (AFM), or displacement on demand (DOD), our simulation testing machine is able to test these intricate components which are so crucial to a quality engine.
Quality control doesn’t stop once the engine is built and stored in inventory. Once we receive your order our experts use your Vehicle Identification Code to verify proper fitment for the part number you are ordering. If any additional information is required to provide the correct part we will work with you or your mechanic to ensure the part is a like-for-like replacement to your old worn out engine. Some online sellers don’t take any action to verify your order is correct for your application, but we go the extra mile to make sure you receive the right part at a Factory Direct price.
Before shipping, our engines are packaged in durable, impact resistant shipping containers.
For engines which will have a ‘core’ returned, we use reusable plastic shipping containers. These containers help to get your product there without damage and also make returning your old ‘core’ engine as simple as possible. Just put your worn out engine in the container, use the adjustable straps to fasten it down and it’s ready to go!
For engines sold outright we use custom made pallets built for the specific engine, then install a plywood crate on the outside of the pallet to protect the engine while in transit.
When it comes to shipping we stick to using the most reliable carriers that boast the highest on-time delivery rates. When it comes to getting your car or truck back on the road sometimes even 1 day can be a big deal, and our fast shipping options ensure your freshly remanufactured engine gets to you as soon as possible.