LEMON Manuals: Even more car manuals for everyone
Home >> Porsche >> 2016 >> 911 Turbo, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 119 (13 - Engine - CRANKGEAR, Pistons -- CARRERA (997)) >> WM 131020 Removing And Installing Pistons And Handling Tools (Except Turbo Coupe, Turbo S Coupe, Turbo S Coupe "Ed. 918 SPYDER", CARRERA 4 GTS, Turbo S CABRIO, Turbo S CABRIO "Ed. 918 SPYDER", CARRERA 4 GTS CABRIO, Gt3, Gt2, Gt3 RS, Gt2 RS, Gt3 RS 4.0) >> Removal >> Removing Pistons - Cylinder Bank 4-6

Removing Pistons - Cylinder Bank 4-6

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2013 Porsche 911, 2012 Porsche 911, 2011 Porsche 911, 2010 Porsche 911, and 2009 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.

Information 

  1. Remove crankcase half.

    → 1001Z1 DISASSEMBLING THE 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 Bridge 9779
      G09816196Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Mark pistons in installation position using a water-resistant marker.
    Fig 2: Locating Mark Pistons (4-6)
    G09816197Courtesy 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)
      G09816198Courtesy 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)
      G09816199Courtesy 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
      G09816200Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 5.2. Replace screws.
  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.
      Fig 6: Pressing Pistons And Connecting Rods (Cylinder Bank 4-6)
      G09816201Courtesy 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)
      G09816202Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 7.2. Replace screws.
  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. Engine type MA.102 (3.6-litre):  Insert piston and connecting rod -1-  in special tool retaining device 9778  (-2-  ).
    Fig 8: Identifying Piston/Connecting Rod In Retaining Device 9778
    G09816203Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 9.1. Engine type MA.101 (3.8-litre):  Pull off 3.6-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.
  10. Check piston for signs of wear.

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



Information 

  1. Remove crankcase half.

    → 1001Z1 DISASSEMBLING THE 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 Bridge 9779
      G09816475Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Mark pistons in installation position using a water-resistant marker.
    Fig 2: Locating Mark Pistons (4-6)
    G09816476Courtesy 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)
      G09816477Courtesy 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)
      G09816478Courtesy 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
      G09816479Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 5.2. Replace screws.
  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.
      Fig 6: Pressing Out Pistons And Connecting Rods (Cylinder Bank 4-6)
      G09816480Courtesy 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)
      G09816481Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 7.2. Replace screws.
  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. Engine type MA.102 (3.6-litre):  Insert piston and connecting rod -1-  in special tool retaining device 9778  (-2-  ).
    Fig 8: Identifying Piston/Connecting Rod In Retaining Device 9778
    G09816482Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 9.1. Engine type MA.101 (3.8-litre):  Pull off 3.6-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.
  10. Check piston for signs of wear.

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

scientia non olet · About LEMON Manuals