United States Air and Radiation EPA420-F-02-035
Environmental Protection September 2002
Agency
Office of Transportation and Air Quality
&EPA Technical
Highlights
How to Maintain or Rebuild Engines
Certified to EPA Standards
The U.S. Environmental Protection Agency (EPA) has adopted
requirements that apply to the process of maintaining or rebuilding
engines. This fact sheet describes these requirements for several types
of highway and nonroad engines. Separate provisions apply to
rebuilding urban bus engines (pre-1994 model year) and locomotive
engines; these 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 the follow-
ing types of engines and vehicles:
• Heavy-duty highway diesel engines (40 CFR Part 86)
• Land-based nonroad diesel engines (40 CFR 89)
• Recreational and commercial marine diesel engines (40 CFR Part
94)
• Land-based nonroad spark-ignition engines (40 CFR part 1048)
• All-terrain vehicles, off-highway motorcycles, and snowmobiles
The provisions we describe in this fact sheet apply generally to any
certified engine. For heavy-duty highway diesel engines and land-based
nonroad diesel engines, the recordkeeping requirements we describe
start with the model years listed in Table 1. The emission-control infor-
mation label on each engine shows its model year and size or power
rating.
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the
requirements?
As someone who maintains or rebuilds engines, you must generally
restore the engine to its original configuration. This keeps the engine
running the way the manufacturer originally designed it to operate, both
for controlling emissions and for achieving the best overall performance.
This adds an assurance that each engine will continue to control emis-
sions, consistent with the manufacturer's original design, throughout its
lifetime.
"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
pistons or power assemblies or make other changes that significantly
increase the service life of the engine. It also includes replacement or
rebuilding of an engine's turbocharger/aftercooler system or its fuel
injection/electronic control system if it increases the service life of the
engine. For these provisions, rebuilding may or may not involve remov-
ing the engine from the truck, equipment, or vessel. Usually rebuilding
does not include following the manufacturer's maintenance instructions
or other routine maintenance; for these simpler service items you still
need to avoid making changes that might increase emissions, but you
don't need to keep any records.
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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
element. 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 there is one.
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is a
You have a reasonable basis if you do two main things. First, you must
install parts (new, used, or rebuilt) so a person familiar with the engine's
design and function would reasonably believe that the engine with those
parts will control emissions to the same degree as with the original parts.
For example, it would be reasonable to believe that parts performing the
same function as the original parts (and to the same degree) would
control emissions to the same degree as the original parts. Second, adjust
parameters or change design elements only according to the original
engine manufacturer's instructions. Or, if you differ from these instruc-
tions, you must have data or some other technical basis to show you
should not expect in-use emissions to increase.
in the
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 an engine if it has no onboard computer.
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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.
the go
No, some restrictions apply. Rebuilt engines should return to the same
type of service (highway, nonroad, or marine). Also, the engine may not
go into trucks, equipment, or vessels that were originally powered by
engines certified to a more stringent level of emission control. Contact us
if this is not clear from the engine's emission-control information label.
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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. If you are a "backyard
mechanic" working on your own engines, we don't require you to keep
any records.
are not
You don't need to keep information that is not reasonably available
through normal business practices. We don't expect you to have infor-
mation that you can't reasonably access. Also, you don't need to keep
any records of what other companies do.
Table 1
Implementation Schedule for Rebuild Recordkeeping Requirements
Application
Highway
Nonroad and Marine
Diesel Engines under
37 kW (50 hp)
Nonroad Diesel
Engines at or above
37 kW (50 hp)
Size Range
all sizes
power < 1 9k W
(power < 25 hp)
19 560 kW
(power > 750 hp)
Model Year
2004
2000
1999
2004
2003
2001
2002
2006
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Application
Marine Diesel
Engines at or above
37 kW (50 hp)
Recreational vehicles
Other Nonroad
Spark-ignition
Engines over 19 kW
(25 hp)
Size Range
displacement < 0.9 L/cyl
0.9 < displacement < 2.5 L/cyl
displacement > 2.5 L/cyl
all sizes
all sizes
Model Year
2005*
2004*
2007*
2006**
2004
*The dates shown apply to commercial marine diesel engines. Requirements related
to recreational marine diesel engines (as identified on the emission-control informa-
tion label) apply two years later.
**Up to half of a manufacturer's sales of off-highway motorcycles and all-
terrain vehicles may be uncertified in the 2006 model year. These vehicles will
not have an emission-control information label and the requirements described
in this fact sheet don't apply to them.
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
• Nonroad spark-ignition engines and recreational vehicles: 40 CFR
1068.120
The provisions that apply uniquely to rebuilding locomotive engines are
described in Requirements for Railroads Regarding Locomotive Exhaust
Emission Standards (EPA420-F-99-036).
For additional information, visit the Office of Transportation and Air
Quality Web site at:
www. epa.gov/otaq
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You can also contact us at:
U.S. Environmental Protection Agency
Office of Transportation and Air Quality
Assessment and Standards Division
2000 Traverwood Dr.
Ann Arbor, MI
Voice-mail: (734) 214-4636
E-mail: ASDinfo@epa.gov
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