United States Air and Radiation EPA420-F-99-045
Environmental Protection December 1999
Agency
Office of Mobile Sources
v°/EPA Technical
Highlights
Rebuilding Diesel Engines
The U.S. Environmental Protection Agency (EPA) has established
requirements that apply to the process of rebuilding or remanufacturing
diesel engines. This fact sheet describes these requirements for
highway, nonroad, and marine diesel engines. Separate provisions that
apply to rebuilding urban bus engines (pre-1994 model year),
locomotive engines, and certain highway engines are not described
here.
To which engines does this apply?
You will need to meet these requirements if you are rebuilding an engine
that has been certified to meet certain emission standards for heavy-duty
highway diesel engines (40 CFR Part 86), nonroad diesel engines (40
CFR 89), or marine diesel engines (40 CFR Part 94). These provisions
apply generally to any certified engine, but the record keeping require-
ments start for the model years listed in Table 1. The label on each
engine should show its model year and size or power rating.
What's the general principle behind EPA's rebuilding
requirements?
As a rebuilder, you in general must restore the engine to its original
configuration.
> Printed on Recycled Paper
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What does EPA consider "rebuilding"?
Rebuilding refers to a partial or complete rebuild of an engine or engine
system. This includes a major overhaul in which you replace the engine's
power assemblies. It also includes replacement or rebuilding of an
engine's turbocharger/aftercooler system or its fuel injection/electronic
control system. For these provisions, rebuilding may or may not involve
removing the engine from the truck, equipment, or vessel. For routine
maintenance or service, you still need to avoid making changes that
might increase emissions, but you don't need to keep any records.
How do I meet the rebuilding requirements?
You must have a reasonable technical basis for knowing that you are
rebuilding the engine to its originally certified configuration for all the
relevant tolerances, calibrations, and specifications that might affect
emissions. You may use new, used, or rebuilt parts, but you should have a
reasonable technical basis for knowing that the parts perform the same
function as the original parts. You should follow the original engine
manufacturer's instructions if you change any parameter or design ele-
ment. Also, be sure to check, clean, adjust, repair, or replace all critical
emission-related components as needed according to the original
manufacturer's recommended practice. This includes the catalytic con-
verter or other aftertreatment device, if the engine has one.
What about diagnostic codes in the engine's
computers?
Don't erase or reset emission-related codes or signals without diagnosing
and responding appropriately to the diagnostic codes. Clear all codes
from diagnostic systems when you return the rebuilt engine to service.
Don't disable a diagnostic signal without addressing the problem. This
doesn't apply to engines without onboard computers.
Can I make any changes to improve the engine?
Yes. You may make changes if you have data or some other technical
basis to show that emissions will not increase. Also, you may use differ-
ent than original parts or make other adjustments if they make the engine
operate like one of the engine manufacturer's newer certified models.
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May the rebuilt engine go into any vehicle,
equipment, or vessel?
No, some restrictions apply. Rebuilt engines should return to the same
application (highway, nonroad, or marine). Also, the engine may not go
into trucks, equipment, or vessels that were originally powered by en-
gines certified to a more stringent level of emission control. Contact us if
this is not clear from the engine labels.
What records do I need to keep?
Keep the following records for at least two years:
• the hours of operation (or mileage or other indication of age) at time
of rebuild
• the work performed on the engine
• emission-related control components you worked on, including a
listing of parts and components you used
• engine parameter adjustments
• emission-related codes or signals you responded to and reset.
You may keep records based on engine families rather than individual
engines if that's the way you do business. Keep the records in any format
that allows us to review them if we ask.
What records don't I need to worry about?
You don't need to keep information that is not reasonably available
through normal business practices. We don't expect you to have informa-
tion that you can't reasonably access. Also, you don't need to keep any
records of what other companies do.
For More Information
See the following regulations for a more detailed description:
• Heavy-duty highway engines: 40 CFR 86.004-40
• Nonroad diesel engines: 40 CFR 89.130
• Marine diesel engines: 40 CFR 94.11
The provisions that apply uniquely to rebuilding locomotive engines are
described in Requirements for Railroads Regarding Locomotive Exhaust
Emission Standards (EPA420-F-99-036).
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For additional information, visit the Office of Mobile Sources' web site
at:
http://www.epa.gov/oms/
You can also contact Tom Strieker at:
U.S. Environmental Protection Agency
Office of Mobile Sources (6403J)
401 M Street, SW
Washington, DC 20460
(202) 564-9322
e-mail: stricker.tom@epa.gov
Table 1
Implementation Schedule for Rebuild Recordkeeping Requirements
Application
Highway
Nonroad and Marine
Engines <37 kW
(50 hp)
Nonroad Engines
>37 kW (50 hp)
Marine Engines
>37kW
Size Range
all
power < 19kW
power < 25 hp
19 <, power < 37 kW
25 <, power < 50 kW
37 <. power < 75 kW
50 £ power < 100 hp
75 £ power < 225 kW
100 £ power < 300 hp
225 < power < 450 kW
300 <• power < 600 hp
450 <, power < 560 kW
600 < power < 750 hp
power > 560 kW
power > 750 hp
displacement < 0.9 L/cyl
0.9 £ displacement < 2.5 L/cyl
displacement > 2.5 L/cyl
Model Year
2004
2000
1999
2004
2003
2001
2002
2006
2005
2004
2007
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