Scope Of Work (SOW). General Overhaul Of The Continental .

Scope Of Work (SOW)General Overhaul Summary (GOS)Continental AVDS 1790-2 Series

Let’s start at the beginningThere are two different of customers:1. Customers that send their engine to usfor rebuild and return R&R.2. Others that require our companyprovided overhauled units outright.Engines arrive by to the shop in many differentconditions.First thing when received we check the the unitsfor any damage during transportation.

As soon as possible we open thetransportation container and checkvisibly the status of the engine. Wereport immediate to the supplier anydiscrepancies, such as, broken engineblock or missing items.Then we record all data on the enginecomponents such as serial and modelnumbers.

Disassembly and CleaningAs we dissemble the engineevery part will get a label andgo to the correct departmentin the shop.The disassembled engine block will be washed by 60degree Celsius and a pressure of 50 bars. After thisprocess the block will go in to a chemical bath forcleaning the long bore holes from all oil sludge, dirt,and carbon.After the chemical bath anddrying we do a more intenseinspection, using specialborescope with camera.

Continuing the cleaning and inspectionprocess on the crankshaft we lookespecially for overheated spots on walland taps.Measuring of the main and connectingrod bearing taps checking tolerance. (wedismantle the caps on the connecting rodside depending on the model of thecrankshaft)Now we begin testing the crankshaft forcracks by magnaflux method.Technical reports of the crankshaft will bekeep on file in our facility.Upon approval of thecrankshaft, we can start withthe assemblyof the engine.For all mandatoryreplacement parts We useonly high quality OEM orequivalent products thatmeet or exceed the toughestcustomers expectations. Wedo not use old stock or newsurplus parts these itemsand will not compromise theperformance of the engine.

The same policy for high quality components is our standardthroughout engine to include, the pistons, piston ring sets, andbearing half sets.As shown in thepicture we colorevery nut after weset it on torque(NM).We also put an extrasecurity, as we haveseen too manyengines nuts missingand very loose.Of course standardthe main bearingsalso have securitywire.

Cylinder ProcessThe Cylinders also undergothe high pressure steamcleaningaspreviouslydescribed and are inspected.If accepted the cylindersthen are subjected to a 2 daychemical bath in order toremove all debris inside thehard to reach areas of thisitem.Now inspected again andmeasured to determinewhat course of action mustto take to restore them tooriginal condition. In mostcases we have found theyrequire re-metallization toreturn to standard size.

We do not re-sleeve the cylinders.There is another method of reconstituting that is muchbetter and guarantees superior performance.Prior to installing cylinder to the blockthe Connecting Rod must be measured inaccordance TM. We check visual andmake a crack test. Also we take care thatwe have the same weight for all 12 rods.If everything is approved we can take thenew bearing half set and start toassemble the c- rod to the Crankshaft.After that, we assemble piston withpiston rings and cylinder to the top of thec- rod and mounting it complete on theengine. We also use an extra sealingagainst leaking by the feet of the cylinder.High temperatures like in the Middle Eastand North African countries will avoidleaking.

Oil PumpAgain, each oil pumpvisibly checked fordamages and thendisassembled.As is true with allcomponents the TMprocedures for properrebuild are followed.Pressure benchtesting each pumpand valve insures thatthe required volumesare met.Added extra security on the bolts as seen in the picture.There are also 6 other bolts secured with wire.

The timing drive gear clutches for the fuel pump and impellers areinspected and every item that is not in tolerance will be replaced.

Few pictures of the high quality factory new andremanufactured parts utilized in our build-up process.

Fuel Pump Metering and DistributionFirst we check the pump on cracks and for leaking of thealuminum housing. The disassemble and inspectionprocedure is ten pages of very detailed requirements, such as,motor head hydraulic, weight, spider, camshaft, etc. For themotor head hydraulic we test every part and if out ofacceptable tolerance it is replaced. (in stock are enough partsto rebuild at least 100 complete pumps) Final assembly test isconducted on Bacharach 8020A machine. Each test certificatereport of the pump will be keep on file in our facility.

Fuel Stop LeversAn imported item, we re-assemble ofcourse with new bearings, washers, etc.Extra care is given to the mechanicalparts from levers to the fuel pumpmetering.

TurboThis is an especially importeditem to get the proper torqueout of the engine. (Air pressure)Upgrading each unit with ourown stocked overhaul kits.We disassemble the wholeturbo, testing the shaft andmeasuring for acceptabletolerances in accordance to theTM.We implement a preferredcleaning/surface treatmentprocedure and DO NOT utilizesandblasting these types ofsensitive parts.

Camshafts, like every part, are first visible inspected, thenmeasured, and magnaflux tested for cracks.Always following the TM procedures.Impellers are very imported for the engine cooling system.We check visual and have found that in most casesreplacement is required due to cracked aluminum anddamage.

Now you can see the engine is slowly coming together.The coolers will be pressure steam washed,chemical bath to take out all the dirt and thenpressure test so we do not have complicationswhen engine is dyno run. After the surfacetreatment they attached to the engine.The oil and transmissioncoolers will be checkedvisible on damages.

ElectricalThe wiring system on the engine is inspectedcompletely and every pole checked for correctfunction.When required wires are replaced.The starter will be inspected to seeif it is suitable for rebuild. Of coursewe re-place all needed items in thestarter correctly overhaul by ourspecialists who follow the TM.The above starter was very damagedand was replaced with a suitableunit.

650amp Generator (C – Engines)We first have a visual checkon leaking, damage, etc. thendisassemble the generator,check and testing every part.Replace parts kits areinstalled and then assemblyby qualified technicians.Test certifications are kept onfile for each generator.

Air IntakeThis part of the air intakeside after the turbo isalways handled correctlyand is mostly placed withOEM or equivalent parts.Take extra precautionswith the nozzle inside thehousing, checking theclear spray. The igniter onthe other side wemeasure following theTM.

Here also a visual check before the first start on the dyno test bench.

Dynamometer TestBefore we start the dyno test, we check if the engine runs in idle speed 675/725 RPM, for around 10minutes, especially watching for leaking fuel, oil, or air.Then will assemble the impellers and protection plates on the top of the engine.Now we start the engine again and let it run for around 5 to 6 hours in idle speed. We stop the engineand cool down. The next day we do the same, letting the engine run in idle speed. This is done so toassure that the piston rings are seated good with the cylinder sleeve.Day three is the final for the engine. We let it run for around 25 minutes (depends temperature of theengine). And then we start with the dynamometer test.After the test there is one more comprehensive visual inspection.DMWR 9-2815-220 is adhered to during the whole test.Complete DMWR include an TAT Dyno Acquisition data system (show curves of the engine power HP,Torque, and RPM), motor head hydraulic, crankshaft, and cylinder-heads test certificate. Each cert andtest are all kept on file in our facility and scanned for off-site digital backup . per engine.

We hope that this summary scope of work understandable.If you have any further questions or need explanations, don’t hesitate to contact your agent.Please be aware that this engine is much more complicated and have many more parts andassemblies than what we have covered in this scope summary.The maintenance book (TM) is over 850 pages.

Before we start the dyno test, we check if the engine runs in idle speed 675/725 RPM, for around 10 minutes, especially watching for leaking fuel, oil, or air. Then will assemble the impellers and protection plates on the top of the engine. Now we start the engine again and let it run for around 5 to 6 hours in idle speed. We stop the engine