Removing Pistons - Cylinder Bank 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 - TURBO .

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 With Bridge 9779

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Mark pistons in installation position using a water-resistant marker.
   Fig 2: Locating Mark Pistons (4-6)

   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 rods
   2. Connecting rod bolts
      Fig 4: Identifying Connecting Rods And Bolts (4-6)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 5.1. Loosen and unscrew two external serration screws (M10 x 1.25 x 51) -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 connecting rod bolts.
6. Remove pistons 4, 5 and 6 with connecting rods.
   1. 6.1. Unscrew the grip handle on assembly aid 9783  and screw the bar -2-  into a threaded bore on the connecting rod -1-  . Press piston and connecting rod down out of the cylinder bore.

      Hold the piston! 

      Fig 6: Pressing Pistons And Connecting Rods (Cylinder Bank 4-6)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 6.2. Repeat this step for pistons 5 and 6.
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.
      Fig 7: Identifying Connecting Rod Caps On Cylinder Bank (1-3)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 7.2. Replace connecting rod bolts.
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. Insert piston and connecting rod -1-  in special tool retaining device 9778  with piston receiving element 9778/1  (-2-  ).
   Fig 8: Identifying Piston/Connecting Rod In Retaining Device 9778

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 9.1. Carefully remove piston-pin circlips with a small screwdriver.
   2. 9.2. Press out piston pin and set aside immediately with the relevant piston.
10. Check piston for signs of wear.

    → 1310IN PISTON WEAR, WEIGHT GROUPS AND IDENTIFICATION MARKINGS .