GENESIS SHORT BLOCK

When the blocks surface is deformed which at times happens even with new blocks from factory it will need to be corrected. The surface is then milled and corrected within 0.1mm accuracy. With the horizontal face corrected with a perfectly flat surface the meting face is improved which also improves sealing characteristics for maintaining the right combustion gas pressure.


The horizontal surface face of the block is measured precisely with a dial gauge for the optimum results.	With the Milling machine making a perfectly flat surface cut with the strictest tolerances possible we are extremely meticulous with the measurements, room temperature settings, setup process and even the speed and timeframe of how each and every block is processed.

Boring the block with the dummy head attached greatly enhances the machining results so that during the boring process the block is not deformed more than 0.01mm. This is another key factor in achieving the highest precision possible with each engine build. The block is assembled with a dummy head (of the same height as the stock head), head gasket and crank caps to replicate the same condition as an assembled engine.


The crank caps are installed with the required torque settings.	The head gasket is fitted with the right torque settings

Boring with the dummy head helps improve the precision of each of the cylinder dimensions which minuses’ distortion. The results of boring the block with the dummy head attached are the best results for precision.


Each piston size is measured for finding the right size in which the cylinder should be bored at for the best piston to cylinder wall clearance.	All machining is also processed in a climate controlled room where the temperature is maintained at a set ideal temperature to minimize the metal expansion for precision cutting.

The small grooves made by the general honing is processed called the “cross hatch” style on the cylinder walls helps with holding oil on the cylinder wall surface for the best lubrication results for the pistons. The general rough surface finish of the cylinder walls will usually cause unwanted frictions. The Plateau honing with the Cross Hatch layout will help smooth the surface more whilst still holding oil in the walls and greatly reducing fiction which greatly enhances the engines life and durability.


The plateau honing cross hatch can be seen on the cylinder walls surface.

The block is then left in the climate controlled room for a minimum of 24 hours to maintain a stable temperature at 20℃, this is the best temperature for checking and verifying piston clearance with tolerances kept within an acceptable range of ±5μ.

To maintain precision and the cylinder block is checked for any signs of imperfection from any unwanted burr and or debris that was caused during casting at the OEM manufacturer. This assures no unwanted matter will cause any harm during assembly and more importantly keeping the oil and waterlines completely clean to eliminate any troubles.

Complete cleaning of the water & oil lines is meticulously done by hand manually with each and every block with every orifice and areas checked thoroughly and then finished off with a high pressure and hot wash in a specialized machine and finally completed with a high pressure air clean in every line, gaps and orifices. This extensive 3 stage process is time consuming but an absolute must to completely eradicate any unwanted burr and foreign material from causing harm to the internals.

The Tomei products have already been checked and balanced when we packed them in the beginning. But we then re-check the weights again in various assembly stages when we assemble the short block. After the conrod and piston is assembled together we then again re-check the combined weights again to make sure that the weight difference is within 0.1g from each other conrod and piston assembly. This will yield the best response, added power, smoother operations and extending engine life and durability.

The dynamic balancing of the crankshaft helps improve response, extra power gains, significally reduces unwanted vibrations which eases the stress on bearings to minimize rebuilds. The crankshaft is also checked for any signs of bends in the crank and for any other faults and if found it will be corrected during this process. Just another time intensive process that you will no longer have to worry about.

Each bearing clearance is carefully checked for guaranteeing that the right amount of oil film is maintained in the right areas for optimum lubrication of the crankshaft without causing any unwanted friction. The thrust direction is also checked and this entire process is also performed in a climate controlled room with all parts and essential equipment maintained at a constant 20℃

The Piston Ring is designed to provide the best sealing properties and clearance. These piston rings are designed as a perfect circle for the protection of the cylinder walls and for maximum sealing properties. This also aids with the best protection possible for the cylinder walls for extending the life of the engine.

The final and most vital process is the complete assembly process is performed in the strictest standards with a clean environment in a stable climate controlled room in-house. All attention to details ensures "Precision & Perfection" that is the Tomei Powered standards and custom.