Installing Pistons - Cylinder Bank 4-6

Preliminary work: Crankshaft is inserted in crankcase half 4-6; pistons and connecting rods are pre-fitted.

Secure the crankshaft to the main bearing in the middle using holding bridge 9779 -1- .
1. 1.1. Tighten two fastening screws -2- hand-tight.
  
  Fig 1: Holding Crankshaft Bridge 9779
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tighten three screws (M8 x 1 x 25) -2- securing the vibration damper to the crankshaft flange hand-tight.
1. 2.1. Turn the crankshaft using turning device 9773 -1- so that the con-rod journal is at bottom dead center position.
  
  Fig 2: Turning Crankshaft (Without Vibration Damper)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Information
  - The parting surface between the connecting rod and connecting rod cap is broken during the manufacturing process.
  - Assign connecting rod cap to the relevant connecting rod immediately after removal.
  - Also check the four-digit matching number.
  - Replace connecting rod bolts.
  - Replace connecting rod bearings.
Check that the new con-rod bearing shells are seated correctly (check locking lugs).

Fig 3: Locating Locking Lugs To Connecting Rod Bearings
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 3.1. Check allocation of connecting rod to connecting rod cap (matching number -1- and data matrix code).
  
  Fig 4: Identifying Connecting Rod On Crankshaft
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install piston and connecting rod.
1. 4.1. For re-installation, fit the relevant piston into the related cylinder bore according to the inscription -4, 5, 6- .
  
  Fig 5: Locating Pistons Installation Position (4-6)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 4.2. Check installation position of pistons. The cone-shaped neck -1- must be facing the intake side -E- . The matching number and data matrix code on the connecting rod -2- must be facing the exhaust side.
  
  Fig 6: Identifying Matching Number On Connecting Rod
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 4.3. Align piston rings. Offset the ring gaps by 120°. Check the twist lock -arrow- at the second ring groove.
  
  Fig 7: Locating Twist Lock On Second Piston Ring
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 4.4. Coat piston and tools funnel 9784 (3.6 l) or funnel 9784/2 (3.8 l) with new engine oil.
5. 4.5. Insert the piston -1- as far as required into the assembly funnel -2- until the lower edge of the piston is flush with the surface of the tool.
  
  Fig 8: Identifying Lower Edge Of Piston Flush With Surface Of Assembly Funnel
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. 4.6. Guide connecting rod and piston -1- into the cylinder bore and position assembly funnel -2- on the crankcase.
  
  Fig 9: Inserting Piston Into Cylinder Bore
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. 4.7. Press the piston into the cylinder bore immediately and hold the assembly funnel -1- firmly while doing this. The wooden handle of a hammer -2- can be used to do this.
  
  Fig 10: Pressing Piston
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. 4.8. Remove assembly funnel.
9. 4.9. Fit the correct connecting rod cap with new screws.
10. 4.10. Repeat these steps for pistons 5 and 6.
Pre-fit connecting rods 1-3 with new bearings and the relevant connecting rod caps and new screws -2- on the crankshaft.

Fig 11: Identifying Connecting Rod Cap On Cylinder Bank (1-3)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 5.1. The matching number -1- and data matrix code are facing the exhaust side.
  
  Fig 12: Identifying Connecting Rod On Crankshaft
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tighten all connecting rod caps -2- according to specifications.
→ Initial tightening: 20 Nm (15 ftlb.)

→ Final tightening - torque angle: 80°

Fig 13: Identifying Connecting Rod Cap Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit rubber sleeves on connecting rods 1-3 to protect the cylinder lining (assembly aid 9795 ).
Remove vibration damper in order to install the crankcase half.

Preliminary work: Crankshaft is inserted in crankcase half 4-6; pistons and connecting rods are pre-fitted.

Secure the crankshaft to the main bearing in the middle using holding bridge 9779 -1- .
1. 1.1. Tighten two fastening screws -2- hand-tight.
  
  Fig 1: Holding Crankshaft Bridge 9779
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tighten three screws (M8 x 1 x 25) -2- securing the vibration damper to the crankshaft flange hand-tight.
1. 2.1. Turn the crankshaft using turning device 9773 -1- so that the con-rod journal is at bottom dead center position.
  
  Fig 2: Turning Crankshaft (Without Vibration Damper)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
- The parting surface between the connecting rod and connecting rod cap is broken during the manufacturing process.
- Assign connecting rod cap to the relevant connecting rod immediately after removal.
- Also check the four-digit matching number.
- Replace connecting rod bolts.
- Replace connecting rod bearings.
Check that the new con-rod bearing shells are seated correctly (check locking lugs).

Fig 3: Locating Locking Lugs To Connecting Rod Bearings
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 3.1. Check allocation of connecting rod to connecting rod cap (matching number -1- and data matrix code).
  
  Fig 4: Identifying Connecting Rod On Crankshaft
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install piston and connecting rod.
1. 4.1. For re-installation, fit the relevant piston into the related cylinder bore according to the inscription -4, 5, 6- .
  
  Fig 5: Locating Mark Pistons Installation Position (4-6)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 4.2. Check installation position of pistons. The cone-shaped neck -1- must be facing the intake side -E- . The matching number and data matrix code on the connecting rod -2- must be facing the exhaust side.
  
  Fig 6: Identifying Matching Number On Connecting Rod
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 4.3. Align piston rings. Offset the ring gaps by 120°. Check the twist lock -arrow- at the second ring groove.
  
  Fig 7: Locating Twist Lock On Second Piston Ring
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 4.4. Coat piston and tools funnel 9784 (3.6 l) or funnel 9784/2 (3.8 l) with new engine oil.
5. 4.5. Insert the piston -1- as far as required into the assembly funnel -2- until the lower edge of the piston is flush with the surface of the tool.
  
  Fig 8: Identifying Lower Edge Of Piston Flush With Surface Of Assembly Funnel
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. 4.6. Guide connecting rod and piston -1- into the cylinder bore and position assembly funnel -2- on the crankcase.
  
  Fig 9: Inserting Piston Into Cylinder Bore
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. 4.7. Press the piston into the cylinder bore immediately and hold the assembly funnel -1- firmly while doing this. The wooden handle of a hammer -2- can be used to do this.
  
  Fig 10: Pressing Piston
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. 4.8. Remove assembly funnel.
9. 4.9. Fit the correct connecting rod cap with new screws.
10. 4.10. Repeat these steps for pistons 5 and 6.
Pre-fit connecting rods 1-3 with new bearings and the relevant connecting rod caps and new screws -2- on the crankshaft.

Fig 11: Identifying Connecting Rod Cap On Cylinder Bank (1-3)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 5.1. The matching number -1- and data matrix code are facing the exhaust side.
  
  Fig 12: Identifying Connecting Rod On Crankshaft
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tighten all connecting rod caps -2- according to specifications.
→ Initial tightening: 20 Nm (15 ftlb.)

→ Final tightening - torque angle: 80°

Fig 13: Identifying Connecting Rod Cap Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit rubber sleeves on connecting rods 1-3 to protect the cylinder lining (assembly aid 9795 ).
Remove vibration damper in order to install the crankcase half.