In the heart of a workshop in Governador Valadares (MG), heavy engines are given a second life. They arrive burnt out, noisy, worn. And they leave with renewed pistons, adjusted cylinder heads, rebalanced crankshafts.
Behind this rebirth lies the almost surgical work of professionals like mechanical engineer Iure Cardoso Maciel , the technical manager of Forte Motores , where he oversees the entire diesel engine reconstruction process.
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Since 2024, leading this operation, Iure not only supervises the technical processes but also gets involved in every detail: from the initial diagnosis to the final bench test.
“ Rebuilding an engine requires more than technical knowledge. It’s precision, patience, and respect for the machine’s original design ,” says the engineer, who has over a decade of experience in industrial and heavy maintenance.
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The Art of Bringing Power Back
Regrinding an engine is not simply “fixing it.” It means dismantling it completely, diagnosing internal faults invisible to the naked eye, correcting deformations, replacing parts, restoring minimal clearances — all while respecting factory standards.
At Forte Motores, around 20 engines per month go through this process. They come from trucks, agricultural machinery, tractors, harvesters. All with stories from the field, the road, or the worksite. All, inevitably, marked by time.
“ We start with a complete disassembly. Then we take measurements with high-precision instruments: micrometers, bore gauges, dial indicators ,” explains Iure. From there, the components are classified: what can be kept, what needs machining, and what must be replaced.
The engine block may receive a new seating, the crankshaft can be reground to spin smoothly again, pistons can receive new liners. In the end, everything is carefully assembled and tested, as if it had just left the production line.
An Investment Worth the Torque
Reconstruction can be up to 60% cheaper than buying a new engine. And the savings are not only financial: the environmental impact is also reduced.
“An engine rebuild avoids the disposal of hundreds of kilos of steel and aluminum. In addition, it consumes less energy and fewer natural resources than manufacturing new parts,” points out the engineer.
This trend gains strength especially in times of economic crisis, when the dollar exchange rate and the scarcity of imported parts make new engines almost inaccessible.
For transport companies and rural producers, keeping the fleet running is a matter of survival. And regrinding presents itself as a technical and viable alternative — with guaranteed durability and performance.
From the Workshop Floor to Technical Leadership
Before leading teams and processes, Iure began his journey with his hands covered in grease. He entered the sector in 2014 and since then has worked in workshops, engineering companies, construction firms, and, in 2023, joined John Deere, the American giant in the agricultural sector.
There, he worked as a mechanic, later as a product specialist, and today he holds the position of Technical Leader at the Inova Equipamentos dealership.
Last year, he was one of 300 Brazilians selected in the technical excellence exam promoted by John Deere across Latin America — recognition that confirms his ability to combine theoretical knowledge with practical application.
“ These experiences gave me a broad vision: from field operations to strategic analysis. And that helps a lot when making decisions in the rebuild shop. Every engine has a story. We need to understand the usage, the wear, the client’s expectations ,” he says.
Engineering with Precision and Sensitivity
The technology of modern engines demands much more than just knowing how to listen to a strange noise.
They are integrated systems of electronic injection, emission control, sensors, and control modules. “ Today, rebuilding an engine also requires understanding software, diagnostic protocols, and even embedded electronics ,” he explains.
To keep his team sharp, Iure promotes regular internal training sessions at Forte Motores.
“ Continuous training is essential. A machining error of just a few millimeters can compromise the entire functioning of the engine ,” he warns.
That’s why the company also invests in quality control and strictly follows ABNT standards and manufacturers’ specifications.
The Future of Engine Rebuilding is Digital
If today the work already demands almost artisanal precision, the future promises even greater sophistication. Maciel believes that automation and artificial intelligence will transform the sector.
“ We already have management software that tracks every step of the process. Soon, connected sensors will be able to indicate component wear in real time, anticipating failures and scheduling maintenance before problems occur .”
While this is not yet reality for most Brazilian workshops, it is the accumulated experience, combined with technical rigor, that makes the difference.
“When a client brings in a damaged engine, they are trusting that we will return not just the machine, but their productivity. That responsibility drives everything we do,” he concludes.
Engine, Mind, and Hands
More than just parts fitting together, gears turning, or cylinders aligning, engine rebuilding is, at its core, an exercise in reconstruction. It is about restoring power, balance, and confidence to the equipment that sustains agribusiness, logistics, and infrastructure in the country.
And it is this work — often invisible to the general public — that takes shape in the hands of professionals like Iure Cardoso Maciel. There, among the noise of lathes, the shine of oil, and the precise dance of micrometers, lives an engineering that beats strongly, like a newly rebuilt engine.
The article is contributed by Juliana Braga and was originally published on December 14th, 2024 .
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