Precision Engine Machining – Cylinder Blocks, Cylinder Heads & Large Diesel Engine Components

Professional Machining for Engine Rebuilding, Industrial, Marine and Heavy-Duty Diesel Engines

Professional engine rebuilding starts with accurate inspection, dimensional measurement and precision machining of the relevant engine components.

We machine cylinder blocks, cylinder heads, connecting rods and a wide range of engine and mechanical components using our own workshop machinery. In addition to conventional automotive engine machining, we are equipped to handle large and heavy components from industrial, marine and heavy-duty diesel engines.

Our services include cylinder boring, honing, plateau honing, milling, turning, cylinder liner seat machining, main bearing tunnel machining, cylinder head resurfacing, valve seat machining and individual component manufacturing.

With a maximum bore diameter of up to 350 mm, a maximum honing length of 1,000 mm, the capability to machine engine blocks weighing up to 1,800 kg, and milling capacity for components up to 1,200 × 3,000 mm, our workshop is also suitable for engine components considerably larger than those typically found in passenger cars.

Cylinder Block Machining

Cylinder wear, damaged liner seats, distorted deck surfaces or deviations within the main bearing tunnel can make proper engine rebuilding impossible without precision machining.

Before machining begins, the relevant dimensions and surfaces are inspected and measured in order to determine the required machining process.

Our cylinder block machining services include:

cylinder boring
cylinder honing
plateau honing
controlled cross-hatch honing
machining of cylinder liner seats
repair of damaged cylinder liner bores and seats
fitting and installation of new cylinder liners
engine block deck machining
engine block resurfacing
machining of main bearing tunnels
dimensional inspection
bore geometry inspection
alignment and straightness inspection

By combining boring, honing, milling and precision measurement, several machining operations can be carried out as part of one coordinated engine rebuilding process.

Cylinder Boring up to 350 mm

Our equipment allows us to machine cylinder bores with diameters of up to:

350 mm

This machining range enables us to work not only on passenger car and commercial vehicle engines, but also on substantially larger engine components used in industrial and marine applications.

Cylinder boring may be required when cylinder wear exceeds the permissible dimensional limits or when a cylinder bore must be prepared for an oversize piston or a repair liner.

The required machining dimension is determined based on the component condition, available replacement components and the intended engine configuration.

Cylinder Honing up to 1,000 mm Length

Honing is one of the most important finishing processes in professional engine rebuilding.

Our honing equipment allows us to machine bores with:

Maximum bore diameter: 350 mm

Maximum honing length: 1,000 mm

This makes it possible to process both conventional automotive cylinder blocks and substantially larger diesel engine components.

Before honing, the bore geometry is measured and evaluated. Depending on the condition of the cylinder, honing can be used either as a finishing operation after boring or as part of a controlled reconditioning process.

Cross-Hatch Honing and Plateau Honing

The cylinder surface is not defined by diameter alone.

The microscopic surface structure of the cylinder bore has a major influence on:

piston ring running behaviour
lubrication
oil retention
piston ring sealing
initial running-in behaviour
friction
oil consumption
long-term engine durability

We can produce different honing structures depending on the engine and application.

Our capabilities include:

conventional honing
controlled cross-hatch honing
plateau honing
multi-stage honing processes
surface roughness inspection
final dimensional inspection

Plateau honing reduces prominent surface peaks while maintaining the deeper valleys of the honing structure that are required for oil retention.

This creates a controlled cylinder surface suitable for modern piston ring systems as well as many heavy-duty diesel engine applications.

The exact honing process is selected according to the material, piston configuration, piston ring system and intended engine operating conditions.

We do not machine Alusil or Nikasil cylinder surfaces.

Cylinder Liner Machining and Liner Seat Repair

Replaceable cylinder liners are widely used in commercial vehicle, industrial, marine and heavy-duty diesel engines.

Correct liner installation depends not only on the liner itself but also on the geometry and condition of the corresponding liner seat.

Corrosion, cavitation, previous repairs, mechanical damage or long-term engine operation can damage these areas.

Our services include:

removal of existing cylinder liners
machining of cylinder liner seats
boring damaged liner locations
measurement of existing liner seats
restoration of damaged liner seats
fitting of replacement liners
installation of new cylinder liners
machining following liner installation
final honing to the required dimension

For older engines, where original replacement components may no longer be available, restoration of the existing cylinder block can often provide a technically and economically viable alternative to replacing the complete engine block.

Main Bearing Tunnel Machining

Accurate alignment of the crankshaft main bearings is essential for reliable engine operation.

Deviations within the main bearing tunnel may occur due to:

severe mechanical loading
thermal distortion
previous engine failure
bearing damage
incorrect previous repairs
long-term operation

We can inspect, measure and machine main bearing tunnels as part of the engine block rebuilding process.

Relevant dimensions and geometry are checked before machining.

This allows the condition of the engine block to be evaluated more accurately before final engine assembly.

Engine Block Deck Resurfacing

A flat and dimensionally correct deck surface is essential for reliable sealing between the cylinder block, cylinder head gasket and cylinder head.

We machine engine block deck surfaces using our milling equipment.

Depending on the application, deck machining may be required due to:

distortion
corrosion
gasket damage
previous machining
surface defects
engine overheating
dimensional correction during rebuilding

The surface is measured before machining and checked again after completion.

Milling Large Engine and Mechanical Components

Our milling machine allows us to process large workpieces with dimensions of up to:

1,200 × 3,000 mm

This capacity enables us to machine much more than conventional passenger car engine components.

Typical applications include:

engine blocks
cylinder heads
industrial engine components
marine diesel engine components
heavy-duty mechanical parts
repair components
custom-machined parts
one-off components

We also carry out individual milling operations for components that require repair, modification or dimensional correction.

Large Engine Block Machining up to 1,800 kg

For large cylinder blocks and heavy mechanical components, we operate a boring machine capable of handling engine blocks weighing up to:

1,800 kg

This is particularly relevant for industrial and marine diesel engine rebuilding.

Large engine blocks often exceed the size and weight capacity of machining equipment primarily designed for automotive applications.

Our workshop therefore provides machining capabilities for significantly larger engine components.

Cylinder Head Machining and Reconditioning

Cylinder heads are subjected to considerable mechanical and thermal stress during engine operation.

Typical defects include:

warped sealing surfaces
worn valve guides
worn valve seats
damaged valve seat inserts
leaking valves
cracks
corrosion
thermal damage

We provide comprehensive cylinder head machining and reconditioning services.

Our cylinder head services include:

dimensional inspection
cylinder head resurfacing
sealing surface machining
valve seat machining
valve seat insert replacement
valve seat bore machining
valve guide replacement
valve machining
valve seat geometry machining
pressure testing
crack testing
final dimensional inspection

Cylinder Head Resurfacing

A distorted or damaged cylinder head surface can prevent reliable sealing of the combustion chamber, coolant and oil passages.

The cylinder head surface is inspected before machining.

When required, the sealing face can be machined to restore:

flatness
correct surface condition
reliable gasket sealing
suitable contact with the engine block

Cylinder head resurfacing is performed according to the condition and design of the individual component.

Valve Seat Machining

Precise valve seat geometry is essential for proper cylinder sealing, heat transfer and reliable valve operation.

We use a dedicated valve seat machining machine for the repair and reconditioning of valve seats and valve seat inserts.

Our capabilities include:

machining existing valve seats
removal of damaged valve seat inserts
machining valve seat insert bores
installation of new valve seat inserts
machining different valve seat angles
restoring correct valve seat geometry
adapting replacement valve seat inserts
machining large diesel engine cylinder heads

Valve seat geometry is machined according to the design and requirements of the particular cylinder head.

Valve Seat Insert Replacement

If the original valve seat insert is damaged or no longer suitable for further machining, the insert can be removed and replaced.

The corresponding seat bore can be machined and prepared before a new insert is fitted.

The new valve seat insert is then machined to the required geometry.

This process is particularly relevant for older cylinder heads where standard replacement components may no longer be readily available.

Individual repair solutions may therefore be required.

Valve Guide Replacement and Valve Machining

Excessive clearance between the valve stem and valve guide can affect valve alignment, sealing and oil consumption.

We replace worn valve guides and machine the associated valve system as required.

Depending on the cylinder head design, this may include:

removal of worn valve guides
installation of replacement guides
dimensional inspection
valve machining
valve seat machining after guide replacement
inspection of valve alignment
final valve seat contact inspection

Valve guides and valve seats must be considered as one geometrical system.

For this reason, valve seat machining after guide replacement is an important part of accurate cylinder head reconditioning.

Large Industrial and Marine Diesel Cylinder Heads

Our cylinder head machining capabilities are not limited to passenger car engines.

We also machine larger cylinder heads used in:

industrial diesel engines
marine diesel engines
stationary diesel engines
heavy-duty diesel engines
historic diesel engines

This is particularly useful for older engines and engines with limited spare parts availability.

We do not machine cylinder heads from gas engines.

Pressure Testing and Crack Inspection

Before expensive machining work is carried out, the basic condition of a cylinder head must be assessed.

Depending on the component and application, we can perform:

pressure testing
crack inspection
sealing checks
dimensional inspection
flatness inspection

These procedures help determine whether further reconditioning is technically justified.

Precision Turning and Custom Component Manufacturing

Our lathe is used both for conventional engine rebuilding operations and for individual component manufacturing.

We manufacture and machine components including:

bushings
sleeves
shafts
pins
valve seat inserts
spacers
repair sleeves
repair components
special tools
individual components
custom-made parts

Turning is particularly important when standard replacement parts are no longer available.

An existing component can be measured and, where technically feasible, a suitable replacement or repair component can be produced.

Machining Obsolete and Discontinued Engine Parts

For many historic, industrial and marine engines, spare parts availability has become one of the main challenges in professional engine rebuilding.

A component may be mechanically repairable even when the original replacement part is no longer manufactured.

In these situations, we evaluate whether the original component can be:

machined
repaired
modified
sleeved
fitted with a repair insert
adapted for an available replacement component
reproduced as an individual component

Typical examples include:

bushings
sleeves
shafts
pins
valve seat inserts
repair inserts
spacers
mechanical adapters
special tools

The objective is not simply to reproduce the external shape of a component.

Relevant dimensions, fits, tolerances and functional surfaces must also be considered.

This is where precision machining and reverse engineering complement each other.

Connecting Rod Machining and Reconditioning

Connecting rods are also inspected and mechanically reconditioned in our workshop.

Depending on design and condition, our services may include:

dimensional inspection
connecting rod bore machining
small-end bushing replacement
bushing fitting
bushing honing
inspection of connecting rod geometry
alignment inspection
individual machining operations
modification for specific repair applications

Connecting rod machining is performed according to the required dimensions, clearances and component design.

Crankshaft Inspection, Measurement and Polishing

At present, crankshafts can be inspected, measured and polished in our workshop.

Our services include:

measurement of main bearing journals
measurement of connecting rod journals
dimensional inspection
journal surface inspection
crankshaft runout inspection
assessment of wear
polishing of suitable bearing journals

Crankshaft grinding is currently not performed in-house.

A dedicated crankshaft grinding machine is planned as a future extension of our machining capabilities.

Precision Measurement and Quality Control

Precision machining depends on accurate measurement.

Relevant components and functional surfaces are therefore inspected before, during and after machining as required.

Our measurement capabilities include:

cylinder bore measurement
bearing bore measurement
main bearing tunnel measurement
diameter measurement
roundness inspection
crankshaft and shaft runout measurement
flatness inspection
surface straightness inspection
surface roughness measurement
fit inspection
comparison of nominal and actual dimensions
precision manual measurement

A comprehensive range of precision measuring tools is available in our workshop.

This allows us to determine not only whether a component is worn, but also where the dimensional deviation exists and what machining process is required.

Our Precision Machining Equipment

Our engine machining workshop includes equipment for a wide range of machining processes.

Milling Machine

Used for machining:

cylinder heads
engine blocks
sealing surfaces
large mechanical components
custom parts
repair components

Maximum workpiece dimensions: 1,200 × 3,000 mm

Boring Machine

Used for machining large engine blocks and heavy mechanical components.

Engine blocks up to 1,800 kg

This capability is particularly important for industrial, marine and heavy-duty diesel engine applications.

Honing Machine

Used for precision finishing of cylinder bores and other cylindrical surfaces.

Maximum bore diameter: 350 mm

Maximum honing length: 1,000 mm

Available processes include:

conventional honing
controlled cross-hatch honing
plateau honing

Alusil and Nikasil surfaces are excluded.

Lathe

Used for manufacturing and machining:

bushings
sleeves
shafts
pins
valve seat inserts
repair components
individual parts
special tools

Valve Seat Machining Machine

Used for:

valve seat machining
valve seat insert machining
machining of seat insert bores
installation and finishing of new valve seat inserts
machining of different valve seat angles

The equipment can also be used for large cylinder heads from industrial, marine and heavy-duty diesel engines.

From Passenger Car Engines to Large Diesel Engines

Our machining services are not limited to one manufacturer or one engine category.

Components can be machined from:

passenger car diesel engines
classic Mercedes-Benz diesel engines
commercial vehicle engines
truck engines
Unimog engines
industrial diesel engines
stationary engines
marine diesel engines
historic engines
heavy-duty diesel engines
special-purpose engines

The decisive factor is whether the individual component can be safely mounted, measured and machined within our equipment capacity.

This manufacturer-independent approach is particularly valuable when dealing with older or rare engines where conventional replacement parts are no longer available.

Precision Machining as Part of Complete Engine Rebuilding

Machining individual components should never be considered completely independently from the engine assembly in which they operate.

Cylinder bore geometry, piston clearance, honing structure, bearing alignment, crankshaft geometry, valve guides, valve seats and sealing surfaces all directly influence the final performance and reliability of the rebuilt engine.

Our machining capability is therefore integrated into a broader understanding of diesel engine rebuilding.

Depending on the project, the process may include:

component cleaning and initial inspection
dimensional measurement
assessment of wear and damage
determination of machining dimensions
precision machining
intermediate inspection
final machining
final dimensional inspection
preparation for engine assembly

This coordinated approach is particularly valuable for major engine rebuilds, rare engines and applications where no standard repair procedure is available.

Individual Components or Complete Engine Rebuilding

Customers may send individual components for machining or commission machining as part of a complete engine rebuilding project.

Typical components include:

cylinder blocks
cylinder heads
cylinder liners
connecting rods
shafts
bushings
sleeves
worn mechanical components
damaged engine components
obsolete components requiring individual repair solutions

Before extensive machining work begins, the component condition can be assessed and the technically appropriate repair strategy can be determined.

Machining for Industrial, Marine and Historic Diesel Engines

The older or more specialised an engine becomes, the more important conventional precision machining and individual technical solutions become.

Modern repair procedures often rely on replacing complete assemblies.

For historic engines, industrial engines and marine diesel engines, this may no longer be possible because the required original components are discontinued or unavailable.

In such cases, professional machining becomes an essential part of keeping the engine operational.

Boring, honing, milling, turning, measuring and restoring functional fits can allow existing original components to remain in service.

This combines traditional engine machining with modern precision measurement, individual component manufacturing and practical engineering solutions.

Mechanical Repair Instead of Component Replacement

A damaged engine component does not automatically have to be replaced.

Depending on the type and extent of the damage, machining may allow the original component to be restored.

Possible repair strategies include:

machining worn surfaces
increasing a bore to accept a repair sleeve
restoring liner seats
manufacturing custom bushings
adapting available replacement components
manufacturing individual mechanical parts
correcting sealing surfaces
restoring functional dimensions and fits

This approach is especially important for engines for which replacement components are rare, obsolete or economically impractical.

International Engine Machining Service

We work with customers from Germany and abroad.

Individual engine components can be shipped to our workshop for inspection and machining.

For international enquiries, the following information is particularly useful:

engine manufacturer
engine model
engine type
component description
original part number, if available
approximate component dimensions
component weight for large parts
description of the damage
requested machining operation
photographs of the complete component
detailed photographs of damaged areas
available technical drawings or dimensional specifications

For rare or unidentified components, we can also evaluate the machining possibilities based on photographs, dimensions and the original component.

Precision Engine Machining – Technical Capacity

Our current machining capabilities include:

Maximum bore diameter:
350 mm

Maximum honing length:
1,000 mm

Maximum engine block weight:
1,800 kg

Maximum milling workpiece size:
1,200 × 3,000 mm

Cylinder boring:
Available

Cylinder honing:
Available

Plateau honing:
Available

Cylinder liner seat machining:
Available

Main bearing tunnel machining:
Available

Cylinder head resurfacing:
Available

Valve seat machining:
Available

Valve seat insert replacement:
Available

Valve guide replacement:
Available

Connecting rod machining:
Available

Custom turning and machining:
Available

Pressure testing:
Available

Crack inspection:
Available

Surface roughness measurement:
Available

Crankshaft inspection and polishing:
Available

Alusil machining:
Not available

Nikasil machining:
Not available

Gas engine cylinder heads:
Not processed

Request Precision Engine Machining

Do you require machining of a cylinder block, cylinder head, connecting rod or another diesel engine component?

We handle both standard engine machining work and individual repair projects involving large, rare or discontinued components.

Please provide as much technical information as possible with your enquiry.

For large industrial and marine engine components, please also include the approximate dimensions and weight.

For obsolete components, photographs and existing original parts can often provide the starting point for developing an individual repair or machining solution.