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Fitting Pistons And Connecting Rods

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Prepare pistons and connecting rods for installation in the crankcase half of cylinders 1-3.

Fig 1: Identifying Piston With Connecting Rod
G03092263Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fig 2: Removing And Installing Piston And Connecting Rod
G03092264Courtesy of PORSCHE OF NORTH AMERICA, INC.
REMOVAL AND INSTALLATION PROCEDURE FOR PISTONS AND CONNECTING RODS

No. Procedure Instructions
1(1) Check piston pin circlip Make sure that the circlip is present and seated securely. The circlip has been pre-fitted on one side of the piston pin by the manufacturer. The circlip opening must lie opposite the groove in the piston.
2(1) Insert piston and connecting rod Complete connecting rod support with spacer ring, special tool 9597/1. Insert piston in the retaining device, special tool 9597. The side with the pre-fitted circlip must face downwards. Fit the connecting rod and piston pin. Insert the connecting rod so that the recesses of the connecting-rod bearing twist lock are diagonally opposite the "TOP" marking.
3(1) Fit piston pin circlip Manually insert the new circlip into the conical part of the assembly sleeve, special tool 9603/1.
4 + 5(1) Press piston pin circlip into the assembly tube Place the cylindrical part of the assembly sleeve 9603/1 on the assembly tube of special tool 9602. Use assembly aid, special tool 9500/3, to slide the circlip from the conical part of the assembly sleeve into the assembly tube. Remove assembly aid 9500/3 and visually inspect the correct position of the circlip in the assembly tube from the side.
6 + 7(1) Position piston pin circlip on the piston pin eye Position assembly tube on the piston pin eye. Press pressure pin of special tool 9602 down until the circlip is heard to engage in the ring groove. Visually inspect correct seating.
    It is important to pre-fit the circlip on a firm surface. The circlip must be pre-fitted only immediately prior to fitting on the piston pin eye.
(1) For explanation see Fig 2.
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