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.

   → WM 1001Z1 DISASSEMBLING ENGINE (EXCEPT CAYMAN GT4) .

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 Bridge 9779 For Crankshaft

      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 Marks

   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 For Connecting Rods

   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 Out 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 Bolts On Cylinder Bank 1-3

      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. 123 (3.4-Liter):  Insert connecting rod with piston in special tool Retaining Device 9778  .
   1. 9.1. For Engine Type Ma. 122 (2.7-Liter):  Pull off 3.4-liter piston receiving element and attach Piston Receiving Element 9778/2  .
   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: Identifying Connecting Rod, Piston And Retaining Device 9778

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

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