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Home >> Porsche >> 2008 >> Boxster S, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 13 - Engine - CRANKGEAR, Pistons -- 987-BOXSTER-CAYMAN >> WM 131020 Removing And Installing Pistons (Except CAYMAN Black Edition, CAYMAN S Black Edition, BOXSTER Black Edition, BOXSTER SPYDER, BOXSTER S "PORSCHE Design Edition 2", BOXSTER S Black Edition, CAYMAN R) >> Assembling Pistons/Connecting Rods, Cylinder 1-3

Assembling Pistons/Connecting Rods, Cylinder 1-3

Information 

When removing pistons, the piston-pin circlip always remains in the piston, which is installed opposite the large assembly bore (no chamfer) for the piston pin.

Information 

The lug of the piston-pin circlip must always be touching the contact surface facing the oil piston shank.

Special tool retaining device 9597  with spacer ring 9597/1  .

Fig 1: Identifying Piston Assembly Device 9597
G09585141Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Insert the piston (without piston rings) into retaining device 9597 so that the deep assembly bore for the piston pin in the piston is facing the observer and the remaining circlip is located underneath (check: twist lock of piston ring, second groove, is also pointing towards the observer -arrow-  , arrow opposite piston crown).
    Fig 2: Locating Piston Pin Assembly Bore
    G09585142Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Place connecting rod in piston so that the twist lock of the connecting rod bearing shell is pointing downwards in the connecting rod (i.e. in the direction of the arrow on the piston crown).
  3. Coat piston pin with new engine oil and press it in manually or using the plunger special tool assembly tool 9500  .
    Fig 3: Pressing In Piston Pin
    G09585143Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Insert new piston-pin circlip in the taper of the assembly aid 9603/1  . Position the cylindrical part on the assembly tube of the special tool assembly tool 9602/1  .
    Fig 4: Identifying Assembly Sequence For Piston-Pin Circlip
    G09585144Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Press circlip into assembly tube using the assembly aid 9500/3  .
    Fig 5: Pressing Circlip Into Assembly Tube Using Tool
    G09585145Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Position assembly tube on piston eye and press piston-pin circlip into the ring groove using the pressure pin assembly tool 9602/1  . The circlip must audibly engage.
    Fig 6: Pressing Assembling Piston Pin Circlip
    G09585146Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Check installation position and secure fit of circlip. The lug of the circlip must always be touching the contact surface running in the direction of the oil piston shank opposite the piston ring grooves.
    Fig 7: Identifying Installation Position Of Circlip
    G09585147Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Repeat steps for pistons/connecting rods on cylinders 2 and 3  .
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