Disassembly Tool 9777

Fig 1: Identifying Tool 9777 For Removing/Fitting Piston Pins

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

53-mm insert for 2.9-litre engine (engine type MA.120)
Roll pin (must be screwed in securely)
56-mm insert for 3.4 to 3.8-litre engine (engine types MA.121, MA.102, MA.101)

Fig 2: Identifying Interchangeable Inserts For Tool 9777
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Disassembly tool 9777 must be pushed as far as it will go into the piston pin.
1. 7.1. Hold the tool firmly at the hexagon -1- and turn the hexagon -2- anti-clockwise as far as it will go.
  
  Fig 3: Sliding Tool 9777 Into Piston Pin
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 7.2. Pull out piston pin -1- . Inset shows the tensioned piston pin.
  
  Fig 4: Removing Piston Pin
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 7.3. To loosen the piston pin, turn the rear hexagonal handle -2- clockwise until the pin can be removed.
  
  Fig 5: Turning Rear Hexagonal Handle 2 Clockwise
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
To remove pistons:
8. Assembly aid 9783 must be inserted into the cylinder bore from the oil pan side. Then press out the piston (by tapping lightly on the handle with the ball of your hand).
1. 8.1. Assign the correct piston pin to the piston immediately.
2. 8.2. Fit assembly aid 9795 -1- (rubber sleeve) on the connecting rod to protect the cylinder liner.
  
  Fig 6: Identifying Protective Sleeves 9795 For Connecting Rods 1-3
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Turn the crankshaft to the bottom dead center position U 2/5 marking at the vibration damper and lock at this position using a locating pin (tool 9595/1) -1- .

Fig 7: Identifying U 2/5 Marking On Vibration Damper
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 9.1. Repeat steps 3 to 2 for removing piston 2 .
10. Turn the crankshaft to the bottom dead center position U 3/6 marking at the vibration damper and lock at this position using a locating pin (tool 9595/1) -1- .

Fig 8: Identifying U 3/6 Marking On Vibration Damper
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 10.1. Repeat steps 3 to 2 for removing piston 3.
11. Check piston for signs of wear.
→ 1310IN PISTON WEAR, WEIGHT GROUPS AND IDENTIFICATION MARKINGS .