Alloytec Engine
Product Information
BUILDING THE ALLOYTEC V6
Engine Block Line
- An aluminium precision-cast block, with iron liners inside it, is manually loaded on to the line
- The block casting, which weighs 38kg, undergoes primary machining
- Intermediate washing cleans the block and casting cavities are checked for leaks
- Bearing caps are assembled before the block undergoes final machining to prepare it for the assembly line
- Another high-temperature wash is performed to clean the block before cavity plugs are assembled
- The block has a final inspection before it moves to the assembly line
- A block takes about three hours to go through the block line and weighs 32kg when it comes out, 6kg lighter than when it was loaded
Crankshaft Line
- The crankshaft, a 24kg steel forging, is manually loaded on to the line
- The crankshaft undergoes primary machining before it is cleaned
- Following the completion of machining, the timing wheel is fitted
- The crankshaft is balanced
- The part is then cleaned again before final inspection and is ready to be moved to the assembly line
- The crankshaft typically takes around three hours to go down the line and weighs
- 20kg when it is removed, 4kg lighter than when it started
Cylinder Head Line
- The cast aluminium head, weighing 15kg, is manually loaded to the cylinder head line
- Primary machining takes place before the head is cleaned
- Casting cavities are checked for leaks before assembly of valve seats, guides and camshaft caps
- Final machining is performed before the head is again cleaned at high temperature
- Plugs are assembled before final inspection and heads are moved to the assembly line
- The head typically takes three hours to traverse the line and weighs 12kg when it is removed, 3kg lighter than when it was loaded
Assembly Line
- When parts from each line are completed, they are moved to the assembly line
- Team members assemble valves, springs, caps and camshafts on the cylinder head
- On the cylinder block, team members assemble the crankshaft, main bearings, piston and conrod assemblies and the oil pump
- The oil pan is added, along with cylinder heads, timing drive, the front cover, including water pump, flywheel or flexplate and camshaft covers and the ignition, including coils
- The inlet manifold assembly and wiring harness are fitted before the engine is cold tested
- The exhaust manifold is added and the engine is hot tested
- Each engine typically takes 3.5 hours to be assembled and weighs about 168kg
- The completed engine is boxed and transported to its destination