A Porsche boxer engine removed from the car and ready for rebuild at Auto-Dusza

Engine rebuilds

The boxer comes out of the car, goes onto the bench, and goes back only when everything measures right.

An engine rebuild is the most serious work we do, and we treat it accordingly. We start with diagnosis aimed at one question: does the engine genuinely need opening. Cylinder endoscopy, compression testing, oil analysis and a control unit readout often make a strip-down unnecessary.

If the decision is made, the unit comes out and goes onto the assembly bench. We strip it to the last bolt, measure every component and only then set the final scope. Assembly follows factory torque figures and sequences, with new single-use components throughout.

We know the weak points of each generation: bore scoring in M96 and M97 engines, the intermediate shaft bearing question on early 996s and first-series 997s, and carbon build-up on the intake valves of direct-injection units. None of these are a death sentence for a car, but you need to know about them before ordering parts.

A Porsche boxer engine removed from the car and ready for rebuild at Auto-Dusza
A Porsche boxer engine removed from the car and ready for rebuild at Auto-Dusza
01

Before we open the engine

Plenty of faults that sound terminal turn out to be a sensor, an oil pump or a chain tensioner. That is why full diagnosis always precedes removal, and we show you the results alongside the endoscope images.

02

Air-cooled engines

Classic 911 units have their own requirements: valve clearances, manifold sealing, fan condition and the state of the cooling tinware. We approach these cars differently from a modern water-cooled boxer.

03

Turbocharged engines

On forced-induction units we also check the turbochargers, charge air cooling and oil feed lines. A failing turbo can destroy a freshly rebuilt engine in minutes if it is not replaced alongside it.

04

After the rebuild

A rebuilt engine has a run-in period. We book you in for an inspection and oil change after the first stretch of mileage — that is when we check sealing and what the filter has caught.

02

Frequently asked questions

What does a Porsche engine rebuild cost?

The range is wide, because cost depends on the engine generation and on what the measurements show after strip-down. So we quote in two stages: diagnosis and removal first, then a final estimate based on the actual condition of the parts. Nothing is ordered before you approve a figure.

How long does a rebuild take?

The work itself is typically a few weeks. The longest element is waiting for parts and any machining. We give you a realistic date once the engine is apart and the full scope is known.

Rebuild, or buy a used engine?

It depends on the model and on how long you plan to keep the car. A used engine is cheaper today, but you are buying a history you do not know. On rarer and more valuable cars a rebuild usually makes the better case. We will tell you plainly what makes sense for yours.

Does bore scoring in an M96 or M97 mean a new block?

Not always. In many cases the block can be sleeved or a single cylinder repaired. The decision comes after measurement — only that shows whether the block is worth saving.

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