Removing Pistons - Cylinders 4-6

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. 

1. Remove crankcase half.

   → 1001Z1 DISASSEMBLING ENGINE .

2. Secure the crankshaft to the main bearing in the middle using special tool holding bridge 9779 -1-  .
   1. 2.1. Screw in and tighten two fastening screws -2-  hand-tight.
      Fig 1: Holding Crankshaft Using Holding Bridge 9779-1

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Mark pistons -4, 5, 6-  in installation position using a water-resistant marker. -E-  indicates intake side.
   Fig 2: Locating Piston Marking

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Screw in three fastening screws -2-  for the vibration damper at the crankshaft flange.
   1. 4.1. Turn the crankshaft using special tool turning device 9773 -1-  so that the connecting rod bolts can be reached.
      Fig 3: Turning Crankshaft (Without Vibration Damper)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Remove pistons and connecting rods -1-  on cylinder bank 4-6.
   1. Connecting rod
   2. Connecting rod bolts
      Fig 4: Identifying Connecting Rod Bolts

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 5.1. Loosen and unscrew two M10 external serration screws -1-  on the connecting rod cap -2-  .
      Fig 5: Identifying Connecting Rod Cap Screws

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 5.2. Replace screws.
6. Remove pistons 4, 5 and 6 with connecting rods.
   1. 6.1. On assembly aid 9783 -2-  , unscrew the grip handle and screw the bar into a threaded bore on the connecting rod -1-  . Press piston and connecting rod down out of the cylinder bore.
   2. 6.2. Repeat this step for pistons 5 and 6.
      Fig 6: Pressing Pistons And Connecting Rods

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Remove connecting rods 1-3 -1-  on the crankshaft.
   1. 7.1. Unscrew connecting rod bolts -2-  and remove connecting rod cap and connecting rod.
   2. 7.2. Replace screws.
      Fig 7: Identifying Connecting Rods

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Dispose of con-rod bearing shells.
   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.

   Procedure for replacing pistons or connecting rods: 

9. For engine type MA.104 (3.4-litre):  Insert connecting rod with piston in special tool retaining device 9778  .
   1. 9.1. For engine type MA.103 (3.8-litre):  Pull off 3.4-litre piston receiving element and attach piston receiving element 9778/1  .
   2. 9.2. Carefully remove piston-pin circlips with a small screwdriver.
   3. 9.3. Press out piston pin and set aside immediately with the relevant piston.
      1. Connecting rod with piston
      2. Retaining device
         Fig 8: Holding Piston/Connecting Rod In Retaining Device 9778

         Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Check piston wear during re-installation.

    → WM 131001 PISTON WEAR, WEIGHT GROUPS AND IDENTIFICATION MARKINGS  .