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Porsche 356 engine rebuild

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Porsche 356 engine rebuild – Are matching numbers a guarantee of quality?

Fifteen years after a car is first registered, almost regardless of type, it is decided whether the used car becomes a worn-out car or a classic.

Even though a Porsche almost always has the makings of a classic, it is never certain whether it will survive the phase of improper treatment and inadequate repairs in such a way that, for example, a condition rating of 2 could ever be achieved again. With newer vehicles, a successful and economically viable revival often fails due to the complexity of the cars; with the 356 and the early 911, time and again—without it being apparent at first glance—you are faced with a huge 3D collection of parts: everything that was cheaply available for repairs or even supposed optimisations has been installed over the years.

Time and again, the view prevails that a vehicle with matching numbers—meaning the body, engine and gearbox still carry exactly the numbers the vehicle had when new—protects against such surprises. Unfortunately, that is not the case. Especially with the 356, you find the most curious combinations of type and model year—very few drivers in 1978, for example, bought new pushrods from Porsche if they had been damaged after a hard battle on country roads due to an over-rev. People looked for used replacements and got the good piece running again with a great deal of improvisation. When you dismantle a 356 engine today, you must identify and eliminate old emergency fixes.

However, the example shown here proves it: they still exist—engines that “only” require a complete overhaul. In this case, it is a very late 356 C from 1964. The vehicle was imported from the USA to the Federal Republic of Germany in the 1990s with minor accident damage and then waited decades for repair and restoration. The engine ran, but it consumed too much oil. Dismantling revealed a completely stock engine, without a “quick tune” or mismatched pistons, but with clearly measurable wear.

The ring gear on the flywheel was completely ruined; the crankshaft’s main and connecting-rod bearings were still within tolerance, but had reached the end of their service life. After very extensive cleaning—the early single-grade engine oils were already a major cause of very tenacious deposits—the crankcase was almost perfect. The main bearing tunnel was fully within spec, which is by no means a given. The pistons and cylinders were well beyond the wear limit, certainly also a result of what was evidently gentle, but intensive use in the USA.

The cylinder heads were completely overhauled, the crankshaft was inspected and only lightly ground at the bearing journals. The connecting rods were measured for dimensional accuracy and fitted with new rod bearings. This allowed the crank assembly to be reassembled with new bearings, in compliance with all Porsche specifications. With the pistons and cylinders, there was a rare stroke of luck: a complete, overhauled set of the correct type could be sourced. It was an apparently forgotten, but original set that had been overhauled many years ago at Porsche to the first oversize. But “plug and play” was unfortunately still not possible. The “new” piston rings were stuck in the now completely resinified preservative oil (no one could have expected such a delayed assembly) and threatened to break when freed. With a lot of patience and the right means, the then perfect set could be installed.

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