Any engine, transmission*, differential or suspension can be rebuilt or overhauled to meet or exceed OEM specifications.

* Some Volkswagen Audi Group (VAG) cars (e.g. Audi R8) gearboxes are only available as a complete set.

Rebuilding requires a high level of accuracy and leaves no room for errors. Mechanical faults are not tolerated well by engines, which will let you know, sometimes by not producing the power you expect, and sometimes by a tragic breakdown.

At CSI we apply what we have learned from the aerospace industry where mistakes are fatal.

The next point to consider is preparedness. This involves having the necessary tools, equipment, a clean, well-organised work environment, and clean components.

Our premises house dedicated engine and suspension assembly workshops. Each workshop is equipped with the best tools, equipment and consumables to enable a mechanic to work without interruption or distraction.

All necessary OEM literature is available and strictly followed at every stage of a build.

All spare parts, as well as original parts and components to be reused, are inspected, measured, weighed, documented, checked against manufacturing limits and signed off by our Chief Engineer before the build begins.

From strip to rebuild, each stage of work is documented for our internal report. This report includes inspection results, measurements and weights of all engine components.

The engine inspection process begins during engine disassembly. Wear pattern signatures on the worn engine bearings are examined to determine the alignment of the rotating and reciprocating engine parts.

Engine parts are segregated by material composition and subjected to high-temperature steam, immersion and ultrasonic cleaning to prepare them for detailed inspection.

Engines are inspected by our inspectors in accordance with the original manufacturer’s documentation. Inspection procedures include but are not limited to:

• 10X-40X Power Magnification Visual Examination,
• Parts Corrosion Examination,
• Magnaflux Inspection –
  Both Circular and Longitudinal Axes
• Liquid Dye Penetrant Examination,
• Balance testing for both
  rotational and reciprocating mass parts,
• Eddy Current testing,
• Cylinder induction air flow testing,
• Crankcase cylinder deck height Inspection,
• Connecting rod alignment Inspection,
• Full Dimensional Parts Inspection.

We have implemented a “one engine one man” rule in our workshop. One skilled mechanic builds an engine from the ground up under the supervision of an engineer.

An engine assembly room is assigned for the build and mechanic, for the job.

Five stages of engine assembly are inspected and signed off by the Chief Engine Inspector.

• Engine Parts Preparation
• Crankshaft, Connecting Rod and Cam Assembly
• Sub-Assembly
• Pre-Case Closure
• Final Assembly