Engine Production Testing

    • For Complete or Replacement content level engines to ensure performance meets specification.

    • All Complete or Replacement level engines are 100% dyno tested prior to shipment

      • Includes dynamic engine performance parameters

      • Run engine 25 minutes at key perfomance points

      • Record performance curve increments of 100 rpm from low to high idle at conclusion

      • Test results are logged and archived by serial number for future reference

    • Performance Results

      • Turbo Boost Pressure

      • Engine Horsepower

      • Exhaust Temperature

      • Engine Torque

      • Fuel Burn Rate

      • Oil Pressure

      • Crankcase Pressure (High Idle & No Load)

      • Oil Analysis (Before & After Test)

    • For Long Block or Basic content level engines to ensure performance meets specification

    • All Long Block or Basic level engines are 100% spin tested prior to shipment

    • Process

      • Verification of proper pumping and ensure no frictional losses

      • Test results are logged and archived by serial number for future reference

      • Performance Result

      • Oil Pressure

      • Oil Analysis (Before & After Test)

    • Check for Fuel Dilution and Coolant Contamination

    • Check for Bearing Wear

      • Elemental analysis for wear components using in-house mass spectrometry

    • Ensures part cleanliness

    • Check for external cracks or leaks

      • Component is magnetized

      • Apply Magnaglo® Fluorescent solution to its surface

      • Ultraviolet or “black” light utilized to reveal the smallest surface flaw

    • Check for internal cracks or leaks of all fluid jackets

      • Block off all engine openings

      • Pressurize the engine to detect any leaks

“Five Major” Engine Components Testing

    • Inspected for cracks

    • Milled to ensure flatness

    • Valve seats & guides machined with precision equipment

      9 Point Check:

      • Magnetic particle crack inspection

      • Flatness

      • Leaks

      • Thickness

      • Surface Finish

      • Valve Guides

      • Valve Recession

      • Valve seat run-out

      • Valve face to seat contact

    • Machined with state-of-the-art Rottler F79 Computer Numerical Control (CNC)

    • Ensure all bores meet exacting dimensional specifications

    • Honed with latest technology from Sunnen

    • Wet sleeve engine sleeves are replaced with 100% new sleeves

      7 Point Check:

      • Magnetic particle crack inspection

      • Flatness

      • Leaks

      • Crank bore alignment

      • Cam bore alignment

      • Deck height

      • Counter bores

    • Checked for straightness

    • Crank & piston pin bores are checked for size

    • 100% new bearings and bushings installed

      4 Point Check:

      • Straightness

      • Crank bore size

      • Piston bore size

      • Center to center dimension

    • Dimensionally & structurally inspected

    • Ground and micro-polished to exacting tolerances

      7 Point Check:

      • Magnetic particle crack inspection

      • Rod & main journal diameter

      • Thrust width

      • Nose diameter

      • Rear seal diameter

      • Bend

      • Surface finish

    • Examined & straightened

    • Main journals & lobes checked

    • Machined to ensure proper valve lift & timing

      10 Point Check:

      • Journal diameter

      • Journal taper

      • Out-of-round

      • Surface finish

      • Lobe hardness

      • Lobe lift

      • Lobe Taper

      • Bend

      • Run-out

      • Intake & exhaust base circle run-out

Fuel System Production Testing

    • For both High Pressure Oil & Common Rail Fuel Pumps

    • Tests both Oil pumps & Fuel Pumps simultaneously if applicable

    • “HPOP” Test System

    • Tests up to 50,000 psi or 3,450 bar

    • Ensures pressure & cubic centimeters (cc) flow requirements under controlled duty cycles

      • Low idle

      • Cranking at stated RPM

      • Rated Horsepower

    • For both Rotary and In-Line Pumps

    • Checks balance of cylinder flow at a given pressure

    • For both Single & 2-Stage Injectors

    • Hartridge Fuel Equipment

    • Measures “pop-off” or pressure to open the nozzle

Turbocharger Production Testing

    • To ensure optimal bearing life, reduced noise & vibration

    • Automated BTI Correction Equipment

    • All turbochargers are 100% cartridge balanced

      • Dynamic balance up to 150,000 rpm

      • Balanced to exceed OEM specifications

    • To ensure optimal bearing life

    • BTI & Hoffman Equipment

    • Turbocharger parts are 100% component balanced

      • Dynamic balance up to 2,500 rpm

      • Balanced to exceed OEM specifications

    • Check of bearing housing and turbine shafts

      • Run-out

      • Surface finish

      • Cylindricity

    • Ensures proper function of actuators

    • Used on variable geometry turbochargers