Removing Pistons

CAUTION: Ingress of dirt

Danger of material damage due to blocked oil bores/oil ducts.

→ Absolute cleanliness is essential when working on the engine.

→ Lay removed engine parts on a clean base and make sure to cover them.

→ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

Component overview:

Fig 1: Overview Of Pistons And Cylinders

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Item	Number	Designation	Removal	Installation
1	2	Cylinder housing	Check and clean sealing faces, identify sealing faces (cyl. 1-3 or 4-6)
2	6	Cylinder sleeve	Clean, check for wear, identify (cyl. 1, 2, 3...), assign to pistons accordingly	Only install with a new piston (see Item 7) if required, coat running surface with new engine oil
3	6	O-ring, 104.0 x 2.0		Replace, fit with special grease (000.043.205.10), do not turn
4	12	O-ring, 110.0 x 2.50		Replace, fit with special grease (000.043.205.10), do not turn
5	12	Piston-pin circlip		Replace; ensure correct seating
6	6	Piston pin	Clean, assign to the corresponding piston	Coat with new engine oil
7	6	Pistons	Check for wear (shank diameter), identify according to cylinder sequence	Install new pistons, if required, only with a new cylinder sleeve, coat piston shank with new engine oil
8	6	Piston ring package	Check for wear	Replace if necessary
9	8	Straight pin, A 8.0 x 14	Check for signs of damage	Check for correct seating, replace if necessary
10	2	Cylinder base gasket		Replace, observe installation position (Top marking must be facing the observer)

Removal for cylinder bank 1-3:

Mark pistons in installation position with a paint marker (do not scratch piston crown).

Fig 2: Locating Mark Pistons
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Mark cylinder housing with a touch-up stick and lift it carefully up and off the pistons.
Slide hose pieces or aluminum sleeves over the threaded bolts to protect the pistons and piston rings.
Turn engine clockwise at the crankshaft pulley until piston 1 is at the top dead center.
NOTE:
Loose parts in crankcase
- Risk of engine damage
→ Cover crankcase bores with a clean cloth.
Cover crankcase bores behind the pistons with a clean cloth so that parts cannot fall into the crankcase.
Remove piston-pin circlip on piston 1 on the inside (towards piston 2) using a small screwdriver.

Fig 3: Locating Piston-Pin Circlip
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Slide piston pin out with your hand. Carefully tap it out using a plastic or aluminum mandrel if necessary. Remove piston and place it on a clean surface.
Turn engine clockwise at the crankshaft pulley until piston 3 is at the top dead center.
Remove piston-pin circlip on piston 3 on the inside (towards piston 2) using a small screwdriver.
Slide piston pin out with your hand. Carefully tap it out using a plastic or aluminum mandrel if necessary. Remove piston and place it on a clean surface.
Turn engine clockwise at the crankshaft pulley until piston 2 is at the top dead center.
Remove piston-pin circlip on piston 2 on any side using a small screwdriver.
Slide piston pin out with your hand. Carefully tap it out using a plastic or aluminum mandrel if necessary. Remove piston and place it on a clean surface.

Fig 4: View Of Piston Pins On Outer Pistons
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Check piston shank for wear → 131001 CHECKING PISTON WEAR .
Tap cylinder sleeves out of the cylinder housing. To do this, insert the pressure piece of the pushing device 9660 at the base of the cylinder sleeve and drive the cylinder sleeve out with a plastic hammer.

Fig 5: Driving Out Cylinder Sleeve
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove O-rings from the cylinder housing and O-rings from the cylinder sleeves and dispose of them. Mark cylinder sleeves with a paint marker and assign them to the corresponding pistons.
Complete the same steps to remove pistons for cylinder bank 4-6.
To make the assembly markings (engraved arrow) → Piston installation marking visible on the piston crown, the combustion residues must be removed using an ultrasound bath or a brass brush with solvent naphtha.
The arrow in the center of the piston crown is a colored stamp and is only visible on new pistons.

Fig 6: Identifying Piston Installation Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.