THE REMANUFACTURING PROCESS

Quality Control
AEI puts quality at the top of our list because your product has to last. An intensive process control system is used to monitor all aspects of the remanufacturing process. Components are inspected after each operation and procedure. Only the highest quality parts and machine work are provided.

Engineering
At the Fliteline engine remanufacturing plant, extensive research goes into casting numbers, machining processes and tolerances, new part vendor selections and product applications. In addition, operators go through training that focuses on unique product features and processes. Potential problem areas may then be identified and corrected.

Disassembly
Each core is disassembled and inspected. Those components not suitable for further processing are scrapped. All small parts are cleaned and critical tolerances are checked. Worn parts are scrapped and replaced. All major components (crankcases, cylinder heads) are baked in gas-fired ovens to carbonize grease and dirt. Other components are chemically cleaned.
Components then go through an abrasive blaster that removes all contaminants. Crankcases and cylinder heads are all magnafluxed to check for any cracks not found during visual inspections. Each component then moves to its respective matching area.

Crankcases
All freeze plugs are replaced and the water cavities are pressure checked for integrity.
All holes  are tapped and drilled, passages are cleaned and repaired if necessary.
All cylinder bores are measured and taken to the same oversize dimensions.
Diamond cutting hones are used for final bore sizing to ensure that surface finish requirements are met.
Main bearing boxes are line honed to ensure uniform size and alignment.
New cam bearings are installed and checked for free cam spin.
Crankcases go though a final wash to remove any remaining contaminants from the machining process.

Crankshafts
All crankshafts are checked for straightness before any further processing occurs.
Excessively worn journals are welded, reground and polished to process standards.
Reground journals are blended with the fillet radii to remove any stress risers that could result in crankshaft breakage.
All oil holes are chamfered at the journal surface to remove all sharp edges that could impede oil flow or damage bearing surfaces.

Connecting Rods
Each connecting rod is checked for cracks, damage and straightness.
All crankshaft bores (big end) are resized to new specifications
Where applicable, piston pin bore bushings(small end)are replaced.
Center-to-center length is then measured to ensure process compliance.

Camshafts
After cleaning all cams are inspected for straightness and lobe conformity.
If grinding is required, the cam contour and timing is maintained to original specifications.
All lobes are polished to ensure uniform surfaces and smooth performance.
If non-remanufacturable, new is used.

Cylinder Heads
All cap plugs are replaced.
All cylinder heads are pressure tested to verify water jacket integrity.
All decks are inspected and machined as required to reach required specifications.
Valve guides are resized or replaced as required.
Valve scats remachined with 3 angle cutters for proper flow.
All older heads with non hardened exhaust seats are replaced with hardened scats to allow operation with unleaded gasoline.
After assembly, each valve is vacuum checked to ensure proper seating and sealing.

Final Engine Assembly & Testing
All engines are hand-assembled by senior experienced technicians. Engines are live tested for correct oil pressure, vacuum pressure and compression to ensure that your newly remanufactured engine will provide years of service.

Our Commitment  to You
To offer you the best service possible, we are continually refining our process to provide you with the most up-to-date information possible. We appreciate your business and would like you to feel free to contact us with your thoughts.
We know that in today's market, having the best product is not enough. That's why at American Engine Installation we strive to meet our customers' expectations and offer a limited warranty.