Jedi's Perkins 4-108 Rebuild

Here you can see the crankshaft before it was pulled out and sent out for polishing. You have no idea how messy this process was! Fluids were pouring out everywhere.

Engines sure have a lot of parts in them! The next few pictures show the parts before they were cleaned, the block and head machined, and old parts replaced.

Can you believe that I had spent two hours cleaning the worst of the mess before taking this picture?

You can see the rusty motor mounts on the left. They were bead blasted (sandblasted), primed and repainted.

After four days of cleaning, extensive bead blasting and scraping, followed by coating the steel surfaces with a rust coverter, the parts looked like this:

I purchased a complete rebuild kit for the Perkins 4-108 diesel engine. It contains cylinder sleeves, a complete set of gaskets, etc. This is what you get for $950usd:

Here is a close-up of one of the new cylinder sleeves:

Jerry's Crankshafts is a tiny, hard-to-find shop in Oakland, that does good work at great prices. Jerry polished Jedi's crankshaft:

Here is the crankshft after Jerry worked on it:

Here is the engine block after Stoltz machined it:

Stoltz also worked on the head:

Another view of the head, with the front of the block in the background:

New pistons, after I attached them to the piston rods.

The engine reattached to the oil pan, with the crankshaft and pistons inside:

We are testing the back face of the engine, where it attaches to the transmission, with a micrometer guage.

Here you can see the bell housing attached to the engine, with the micrometer gauge still attached:

Slowly adding more components to the block:

Another shot:

Bryan is getting ready to fire the engine up for a bench test:

You can see the big fat battery cables to the tractor battery on the floor (Jedi has two of these 4D batteries.)

Here you can see that the diesel fuel is coming from a plastic jug. Even though Bryan is smoking, there is no danger of explosion with diesel. It would not ignite even if you threw a match into the jug.