7.3L 1999-2003 Powerstroke Full Running Daily Driver Ford Diesel Crate Engine Choate Performance

The “Daily Driver” model is specifically designed for spirited daily driving, consumer level towing, and everyday life.

 

Key Features and Fixes

Core Performance & Power

• Improved Performance: Rated for 325+ HP capability, delivering significant power over stock for demanding applications.
• Fully Balanced Rotating Assembly: Precision-balanced components ensure smooth, vibration-free operation and extended bearing life at high RPMs.

Reliability & Durability Upgrades

• Seat Cracking Elimination: Upgraded valves and hardened valve seats used to exceed OEM standards. This eliminates the original design’s tendency for parent material seats to crack under heat cycling.
• Enhanced Valve Integrity: Features all-new, upgraded material valves that eliminate the high-heat separation common in OEM exhaust valves, preventing compression loss and piston-to-valve contact.
• Billet Freeze Plugs: Billet freeze plugs that are securely bolted to the block are used, eliminating the failure-prone factory soft plugs which can corrode or blow out under pressure..

Intended Use & Component Specification

• Complete Drop-In Ready: Ships complete with new water pumps, thermostats, OE harmonic balancer, flywheel, turbocharger, and all necessary sensors for a quick and comprehensive installation.

 

Machining Process:

Choate Engineering Performance doesn’t just rebuild engines - we remanufacture them. Each of our engines undergoes extensive, precision machine work to correct OEM flaws and ensure durability and reliability.

Engine Block Machining:

Each of our engine blocks are CNC blueprint machined using state-of-the-art CNC machines. This process ensures perfect dimensions, precise tolerances, and optimal alignment. This starts with decking the surface of the block to achieve the necessary flatness and smoothness (Ra 30 or better) required for flawless sealing with MLS head gaskets. The cylinders are then diamond honed to an extremely tight tolerance to match the piston diameter (within the nearest 0.0001 inch). Following honing, the main bearing bores are line honed to establish a true, straight centerline for the crankshaft. Finally, the cylinder bores are bored to a true 90 degree angle from the crankshaft centerline.

Cylinder Head Machining:

Our cylinder heads are fully machined and enhanced in-house to improve airflow and reliability. Each head is first magnafluxed and pressure tested to ensure they are free of any cracks or leaks. The surface is then precision decked to an extremely smooth finish, guaranteeing the necessary flatness for a perfect seal with MLS head gaskets. Internally, the valve seats are machined to optimize airflow and prevent common failures, and the entire valve train geometry is blueprinted to specific tolerances to reduce lifter preload and prolong component life.

Rotational Assembly Balancing:

The balancing of the rotational assembly is crucial for eliminating vibration and maximizing engine longevity. This precision work involves checking and correcting the balance of the crankshaft, connecting rods, and pistons. The crankshaft is thoroughly checked for run-out and inspected for fatigue before being polished and ground to strict concentricity tolerances (0.0005 or less) to ensure the new bearings receive the best possible surface. Rods are inspected and conditioned, and all bearing clearances checked to ensure proper fitment with the new bearings. Each of the pistons, rings, and pin retainers are meticulously weight matched (to a tolerance of 2 grams or less) prior to crank balancing. Then the entire assembly is dynamically balanced on specialized equipment. This ensures that the engine runs smoothly, minimizing stress on the bearings, and extends the overall life of the components.

 

Components and Parts:

Engine Core Components

• Cylinder Block
• Crankshaft
• Steel Connecting Rods
• Camshaft
• New Pistons
• Reman Cylinder Heads
• New OE Harmonic Balancer
• New Flex Plate (Flywheel is NOT included for manual builds!!!)
• Pushrods
• Main Bearings
• Rod Bearings
• Cam Bearings
• Main Bolts
• Head Studs
• New Lifters
• Rockers
• Billet Freeze Plugs
• Upper Oil Pan
• Lower Oil Pan

Gaskets and Seals

• New Head Gaskets
• Rear Cover and Gasket
• Rear Main Seal
• Front cover and Gasket

Cooling System

• New Water pump
• Thermostat

Sensors and Electronics

• 4 New Oil Rail Plugs
• New ICP Sensor
• New IPR Valve

Miscellaneous

• Turbocharger Turbo
• Pickup tube
• New Injectors
• New Low Pressure Oil Pump
• New High Pressure Oil Pump
• Oil Cooler
• New Oil Filter

Cylinder Head Components

• New Valves
• New Valve Guides
• New Valve Seals
• Threaded Blow Proof Plugs