Porsche Engine Rebuild
Is a Porsche engine rebuild something anyone can do? Almost. But, doing it properly and with the great precision necessary for enduring high performance... few people can do that. It takes years of experience and innate craftsmanship to rebuild a Porsche engine to perform magic. That magic is the ability of a Porsche engine to deliver jaw dropping power after being rebuilt properly---as I do. That's not bragging. That's my reality. Yours if you choose. Jump to transmission rebuild.
Endurance of your Porsche engine & transmission requires both areas receiving proper lubrication. This means:
Maintaining correct levels
Changing lubricants including filters on a regular basis
Using the correct lubricants for your particular engine & transmission
Adding oil radiator(s) for high performance driving
Maintaining clean oil radiators
Preventing / repairing oil leaks
The more frequently engine and transmission oil is changed (and filter) the longer your engine and transmission will endure within the tolerances Porsche engineers specified.
Earlier model Porsches require manual tuning adjustments on occasion. That's the stuff I cut my teeth on. Later model Porsches are computer controlled. I'm scanner savvy. In a nutshell, I've got you covered from nuts & bolts to digital bits & bytes engine tuning.
Porsche Transmission Rebuild
The most noticeable performance decline in manual Porsche transmissions is the ability to shift easily / quickly / cleanly from one gear to the next---up or down. Syncro wear is most often to blame. Given worn syncros, shifting puts gears and dog-teeth at increased risk of damage, particularly if a driver does not shift-compensate for syncro wear. Should you experience any noticeable oddity when shifting, I recommend inspecting this condition sooner than later. Reason being, it's more economical to replace just syncro rings as compared to also replacing ruined gears and/or dog teeth.
'09 model Porsches and up have electronic PDK shifting.
Transmission oil in most cases should be changed every 15,000 miles. Do this regularly and you will go a long way to preserving the integrity, performance, and value of your Porsche transmission.
Porsche Clutch & Flywheel
Clutches & flywheels have a factory prescribed wear limit. Once beyond that limit, driving performance declines. You can extend the life of your entire transmission by driving it correctly. Not sure how to do that... Find out: 305-588-0874
917 Long Tail
917 Short Tail
917 CAN AM Spyder
Following Porsche's Le Mans victory in 1970 and '71, the company redirected their racing efforts to North America and the CAN AM series. Teaming up with the Roger Penske organization, the 917/10 was created with magneseum tubular frame weighing just 100 lbs and a 5 liter turbocharged 12 cylinder engine producing 1,000 hp. In 1972, the 917 was the most powerful racing car in history. On the track, it brought McLaren's CAN AM leadership to a decissive end. The successor to the 917/10 was the 917/30 (the engine increased to 5.4 liters.) In August of 1975, Porsche took the 917/30 to the Talladega race track in an attempt to establish a closed course speed record. With Mark Donahue in the seat, they did so on August 9, 1975 with an average speed of 221.12 miles per hour---a record that endured for 15 years... eventually broken by an Indy car.
PHOTO CREDIT: STOCK
What goes into an engine rebuild? After removing an engine from its chassis, a forensic inspection is done before cleaning, preliminary cleaning, careful disassembly noting any anomalies along the way, preliminary inspection of parts, meticulous cleaning, detailed inspection and measuring of parts, technical evaluation of what needs replacing and what can be machined in order to be intelligently renewed & reused, meticulous reassembly to Porsche factory specs or better, proper break in, first tuning, testing, final tuning, final testing. No short cuts. No distractions are tolerated during critical stages. When new parts are needed, you're advised asap why and ahead of my proceeding unless you authorize my having carte blanche in advance. When your engine rebuild is done in my shop, I'm the ONE & ONLY person doing your engine's rebuild start to finish. My experience & focus ensures you getting peak performance and durability from the investment you make with me to renew your engine's performance.
If you choose, I can do things to make your engine rebuild better than what factory spec calls for. Exactly what this entails depends on the goals you have in mind. In this regard, I can help you understand the options. And, clarify what the results will be for your particular performance interest. Ultimately, you'll have a clear picture of what can be done to your engine during a rebuild, what the added investment is, and what the added performance outcome will be.
Tolerances set by the factory for engine rebuilding... I know most by heart. Still, I always refer to Porsche's written Factory Technical Specs. This process is similar to pilots. Even though they've done the same procedure hundreds or thousands of times, they still refer to a written checklist as I do. The specialized nuances that make for an exceptionally fine engine rebuild... I've learned my craft over 30+ years. I know what I'm doing and then some. Ultimately, you entrust your engine rebuild and the dollars you'll invest to someone who's going to return exceptional performance value to you. That's what you'll get when your engine rebuild is under my authority.
For reading this...
If you're reading this and contemplating an engine rebuild, this is for you: Print this page and present it to me when final payment is due on your Porsche engine rebuild, or transmission rebuild, or both. For doing so, you'll receive 10% off my services. Candidly, if you're on the fence, I hope this offer gets you off and into my shop. Bear in mind this 10% is on my services. It's not on parts, machining or other outside-my-shop work. You'll have a project scope and budget/estimate ahead of any work proceeding so both you and I know what's planned & expected.
Above: Same Porsche engine before and after GP AutoWerks rebuild. With most surfaces bead blasted and refinished with appropriate engine-area coatings (or left bare to match Porsche stock finishing) this engine rebuild is "with restoration"---an owner decision made at the outset of a rebuild. According to customer's goal in this case, work was accomplished to match a stock engine (for the period) as close as possible.
Below: This engine came in running with a noticeable knock. Issue found: whomever had previously worked on this engine failed to install #4 rocker shaft correctly. This led to a binding of the rocker... then that rocker's valve & piston making contact. The crankcase is open here to make an internal inspection. While the problem was the rocker shaft, since there was piston & valve contact, everything that may have been damaged must be inspected so any & all issues are found and corrected. There is no exception to comprehensively inspecting for damage where I'm concerned. In this case, the valve, guide, rocker, rocker shaft, and piston were replaced for #4 cylinder.
Click photos to enlarge
Top: Broken head studs are marked in yellow. Performance declines some from cylinder & heads held unevenly to crankcase. Precise flatness of head surfaces and cylinder faces can be beat out of spec as a result of operating an engine with broken studs. Bottom: ARP studs have replaced all old stock studs. An excellent upgrade as these will last indefinitely.
Engine rebuilds typically begin with a leak-down test. This provides insight to what can be expected during rebuild in regards to valve and piston ring sealing integrity. I can tell if a leak is at the intake or exhaust valve, or rings, or combination---this for each tested cylinder. Leak-down results seen above indicate cylinder #4 being best and #6 the worst. Differences seen here confirm this engine's lacking performance.
Click photos to enlarge
Air cooled Porsche engine thermal performance depends in large part on how clean the engine's exterior surface is. The cleaner the better as this allows heat to more readily escape the engine. It is up to my customer to decide what investment they make in "clean." Engine above has been degreased then media blasted. The alternative is to degrease only. Look at the difference below. Click on photo to enlarge:
One skilled person is capable of correctly & safely handling a Porsche engine during the entire rebuild process provided the equipment required is on hand. Here, I just completed a 3.2 engine rebuild. Am preparing to connect the engine and its' matching transmission prior to returning them as a unit to the Porsche on the lift next to me.
Above: Gears, dog teeth, shift rods, forks, sleeves and bearings are being inspected in this transmission rebuild. If any anomaly is found, it's photo-recorded and immediately text-sent to the owner. I'll call to comment on what is found unless that customer has a standing order for me to make repairs as required.
Right: New flywheel is installed with pilot bearing and new bolts---new bolts are standard procedure as old bolts, once removed, are stretched from the initial torquing and so will not correctly stretch again. Old "doughnut-style clutch disk compared to new spring-style. Doughnuts tended to explode making a mess of components in a transmission's bell housing.
Transmission rebuild completed, the trans is connected to the engine with proper torque settings applied to fasteners. New oil is installed. Flanges on the drive couplings are cleaned and ready to receive the drive shafts/CVs with new gaskets.
Click photos to enlarge
Porsche Rebuild Parts - Aftermarket Parts
By default, I install genuine Porsche or OEM parts when available. If you prefer aftermarket, say so and consider it done whenever possible. If you have any question as to a comparison between a genuine Porsche part and the matching aftermarket part, ask... we'll discuss whatever part is in question and you can make the call, or leave it to me if you prefer. I'm a steward of your budget and always want to deliver optimal solutions for minimal expense, doing so with your input along the way.
Where classic Porsches are concerned, it's more of a challenge to find certain parts. Good news is I have resources across the nation and abroad so tough-to-find parts... I can find them.
Porsche Records / Documentation
Keeping accurate Porsche service & repair records substantiates the care given a car. Such records also provide very valuable reference when planning and engine rebuild / transmission rebuild. Or, working on any area of your car. Benefit being the potential for finding written answers to the questions that may arise before or while work is in progress. In short, I suggest you be a Porsche record keeper if you aren't already.
My GT and GTP class racing experience is at your service. From the simplest of add-ons or refinements to your track Porsche, to extensive build outs for your class, you're in experienced race hands with my shop.
Any and every mating surface on a Porsche engine/transmission rebuild must be very clean and flat. If not, the gasket applied is given the opportunity to leak.
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Porsche® Revive the Passion
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the Greater Miami
4551 SW 71 Ave.
Bay #1, Miami, FL
GP AutoWerks is an independent Porsche service & repair shop located in Miami, Florida, U.S.A. Serving both street and race track enthusiasts, GP AutoWerks provides a full range of Porsche mechanical capabilities from simple adjustments to comprehensive engine and transmission rebuilding for both classic and contemporary Porsches. Porsche, the Porsche crest, and Porsche car model names are under licensed use by Porsche Cars North America, Inc. (PCNA) from the owner Dr. Ing. h.c. F. Porsche Aktiengesellschaft, Porsche AG ("Porsche.") No association or affiliation with Porsche, PCNA or AG is intended or implied by GP AutoWerks who happens to
specialize in service, repair, PPI, modification and restoration of Porsche vehicles. Videos shown are Porsche productions presented for educational & entertainment purposes only. Permission for presentation is on file. Thank you.
Photos of Porsche service & repair, including engine & transmission rebuilds, brakes & suspension, body werks, interior, modification & restoration, and PPI work including parts and cars depict the property of GP AutoWerks' customers. All such images are used in this website with the expressed permission of GP AutoWerks' customers. Thank you.
Photography, unless credited otherwise, is © 2015-2020 Karl Hansen. All rights reserved.
Photo captions are provided to reflect photo content and credits appear where due.
Website © 2020 Karl Hansen. All rights reserved.
Happy Porsche driving! And remember to please buckle up because being glad you did is a wonderful thing ~~~
Independent Porsche Service, Repair & Rebuild Specialist
Porsche: Tune Up, Oil Change, Engine Rebuild, Transmission Rebuild,
Brakes, Suspension, Alignment, Corner Balance, Air Conditioning, PPI
Independent Miami Porsche Service & Repair content for smartphone:
Making the most of your power plant and drive train.
930/Turbo power plant at the beginning of its restoration journey. As you may appreciate from this side view, these engines are plumbing-intense. And beyond the larger control ducts easily seen here are hidden a myriad of even finer lines. Now, imagine taking this entirely apart... then putting it all back together so it runs like a finely tuned watch---that is our expertise.
---If you can do this according to factory specs and with extremely high standards of workmanship, we'd be interested in speaking with you. Please visit our shop with resume and references in hand.
Valve cover being installed. Grey Line gaskets are used as a matter of shop preference. Their sealing performance is beyond all others. Combined with the proper cover cleaning and fastening method, these covers will be vault tight now. This eliminates oil weeping that, when dripping on hot heat exchanges, can ignite and cause an engine fire. It's good thinking to attend oil leaks sooner rather than later.