Removing Pistons - Cylinder Bank 1-3

Information 

• The specified positions relate to removing and installing components on the engine assembly support with the engine in a vertical position. 
• Mark pistons in installation position using a water-resistant marker. 

1. Unscrew screw plug (M30 x 1.5) -1-  for removing piston pins.
   1. 1.1. Replace sealing ring.
      Fig 1: Identifying Screw Plug For Removing/Fitting Piston Pins

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      To remove a piston-pin circlip: 

2. Use turning device 9773  to turn the crankshaft and vibration damper to the bottom dead center position U 1/4 marking  and lock at this position using a locating pin 9595/1 -1-  .
   Fig 2: Positioning Crankshaft At BDC 1/4

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   WARNING: Preloaded or pressurized components

   • Risk of eye injuries
   • Risk of bruising

   → Wear personal protective gear.

   → Secure components to prevent them from falling off suddenly.

   Information 

   • Special tool disassembly tool 9764 for removing piston-pin circlips must only be turned in a clockwise direction. 
   • Always hold the tool firmly with one hand when using it. 
   • Replace removed piston-pin circlips. 
3. Slide special tool disassembly tool 9764  through the assembly bore. The groove for the hook on the circlip -arrow-  must be at 9 o'clock  position when the engine is positioned vertically.
   Fig 3: Locating Groove Position For Circlip Hook (9 O'Clock)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Disassembly tool 9764  must now be pushed into the circlip.
   Fig 4: Positioning Groove Of Special Tool 9764 In Hook On Circlip

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 4.1. Carefully turn the tool to the left and right. You should feel resistance from the hook.
5. Tighten circlip with tool 9764. To do this, turn the hexagonal handle clockwise until you feel a certain amount of resistance.
   Fig 5: Tightening Circlip With Tool

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Keep the hexagonal handle -1-  tight and turn the pipe -2-  clockwise until you feel a certain amount of resistance. At the same time, the cheese head bolt will move horizontally to the left from position A  in the guide groove.
   Fig 6: Positioning Tool 9764 At Position A

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 6.1. Hold the tool firmly at the pipe -2-  and press it slightly against the piston. Slowly turn the hexagonal handle -1-  using spring force until the cheese head bolt is at position B  .
      Fig 7: Positioning Tool 9764 At Position B

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 6.2. Hold the hexagonal handle -1-  firmly and turn the pipe -2-  clockwise until you feel a certain amount of resistance. At the same time, the cheese head bolt will move horizontally to the left from position B  in the guide groove.
      Fig 8: Positioning Tool 9764 At Stop Ahead Of Position C

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   3. 6.3. Hold the tool firmly at the pipe -2-  and press it slightly against the piston. Slowly turn the hexagonal handle -1-  using spring force until the cheese head bolt is at position C  . The circlip engages in the tool with an audible click.
      Fig 9: Positioning Tool 9764 At Position C

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   4. 6.4. Slowly pull the tool and circlip -1-  out of the crankcase. Dispose of old circlips.
      Fig 10: Pulling Tool 9764 Out Of Crankcase

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      To remove a piston pin:  Use interchangeable insert in accordance with the specified engine.