Fitting Pistons And Connecting Rods
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2004 Porsche Boxster, 2003 Porsche Boxster, 2002 Porsche Boxster, 2001 Porsche Boxster, and 2000 Porsche Boxster. However, it is still accessible from the selected car via links, so may be relevant.
Prepare pistons and connecting rods for installation in the crankcase half of cylinders 1 - 3.
REMOVAL AND INSTALLATION PROCEDURE FOR PISTONS AND CONNECTING RODS
| No. | Procedure | Instructions | ||
|---|---|---|---|---|
| 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(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 | 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 bearing twist lock are opposite the piston marking "TOP". | ||
| 3(1) | Fit piston pin circlip | Manually insert the new circlip into the conical assembly sleeve, special tool 9603. | ||
| 4 + 5(1) | Press piston pin circlip into the assembly tube | Place assembly sleeve 9603 onto the assembly tube of special tool 9602. Use assembly aid, special tool 9500/3, to slide the circlip from the conical sleeve into the assembly tube. Remove assembly aid 9500/3 and visually inspect the correct position of the circlip in the assembly tube. | ||
| 6 + 7(1) | Position piston pin circlip on the piston pin eye | Carefully insert the pressure pin of special tool 9602 into the assembly tube until it contacts the piston pin circlip. The circlip can pop out of the assembly tube in the case of improper handling - danger of injury! Position assembly tube and pressure pin on the piston pin eye. Press pressure pin down until the circlip is heard to engage in the ring groove. Visually inspect correct seating. | ||
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