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Join Date: Jan 2010
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Rebuild the DFI engine?????

Hi,
Is it possible to rebuild the new DFI engine??
If the cylinders are welded to the crank case, how is it possible to remove the pistons?
I asked this in another forum and got no answer, I hope to get some answers here.
Thanks.

Old 05-02-2010, 07:32 AM
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the case splits in half the pistons are installed as the case comes together.
Old 05-02-2010, 08:04 AM
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Its like trying to put the pistons from the bottom of the V8 engine. how you gonna attach the tool to compress the rings and position the big case and cylinders over the pistons?
I think at the factory they put the pistons and cylinders in, then they weld the cylinders to the case.
Old 05-02-2010, 12:03 PM
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the case is put together with the cranks and connecting rods assembled. then the pistons are installed from the outside. the piston pins are installed through a hole in the case one at a time then the circlips are installed after each pin. This is a very tedious job. it takes alot of time. If you can find the TV show Ultimate Factories they did the Porsche factory and they show a glimps of the assembly.
Old 05-02-2010, 02:26 PM
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That was a fun show to watch! Basically that is the way the piston assembly goes. The cylinders are not "welded" on, they are cast together with the case halves in a similar manner to the old M96/97 motors but it's a homogeneous material(Alusil) instead of being cast around Locasil liners.
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Old 05-02-2010, 07:34 PM
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Watched this rebuild on a M96 motor. Pretty interesting.


YouTube - glenn986s's Channel

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Old 05-03-2010, 12:21 PM
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