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991.1 Engine swap/rebuild

nmorris1

nmorris1

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My 991.1 2015 GTS burnt an exhaust valve at 26K miles and careful scoping has revealed most of the cylinders have some form of bore score, so the engine has had it. After a failed attempt at getting an factory refurbished engine swap (Porsche no longer have them), I've decided to swap it out myself and then rebuild the old one. I'm documenting the rebuild here if you are interested.
 
Sorry to hear about your trouble. Pity you did not have a warranty to drop this in Porsches lap.

As I am currently in the process of an engine rebuild of a 3.5 Aircooled race engine, that when stripped was discovered to have suffered from poor maintenance, I feel your pain.

One thing I have learnt, fortunatley not to my cost, is that having bores reconditioned is not straightforward. Many offer such services but few can do it properly. Mine are Nikasil but yours are Alusil in a late MA1/03 engine. Apparently Alusil can be reconditioned but its a very specialist job and would need oversize pistons. It seems Hartech know a bit about this for the 991. It may be worth contacting them unless you have already decided to buy new barrels.
 
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