Installing Pistons

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

Install piston.

Fig 1: Overview Of Piston/Connecting Rod
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Piston rings (move gap by 120°)
2. Piston
3. Circlip
4. Connecting rod
5. Connecting rod bearings must always be replaced . Observe relevant classification.
6. Connecting rod bearing cap
7. Connecting rod bolts → Initial tightening: 30 Nm (22 ft lbs.) → Torque angle: 90°
8. Cylinder block
9. Piston pins
1. 1.1. Pull dowel sleeve -arrow- out of the bore hole so that special tool funnel T10333 can be positioned flat on the cylinder block.
  
  Fig 2: Locating Dowel Sleeve On Cylinder Block
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Pfeil - Dowel pin
2. 1.2. Oil the piston well and insert it into the funnel.
3. 1.3. Align all pistons so that the deep valve recesses -1 and 2- are facing the middle of the cylinder block and the arrows -3- on the pistons are facing the vibration damper.
  
  Fig 3: Identifying Cylinder Valve Recesses
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Valve recesses on cylinders 1, 3 and 5
  2. Valve recesses on cylinders 2, 4 and 6
  3. Arrow pointing towards vibration balancer
4. 1.4. Position the piston funnel on the cylinder block and align it so that the high edge -arrow- is facing the middle of the cylinder block.
  
  Fig 4: Positioning Piston Funnel On Cylinder Block
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 1.5. Slide piston fully into the cylinder bore.
6. 1.5.1. Turn the crankshaft back and forth if necessary.
7. 1.6. Insert dowel sleeves back into the bore holes -arrow- .
  Information
  - Oil the bearing shells and bearing with engine oil.
8. 1.7. Oil connecting-rod bearing shells -5- .
  Information
  - The pistons must already be pre-fitted (pistons, piston rings, connecting rods and fastening material) before performing the next step.
  - Note the association between the connecting-rod big end and the connecting-rod bearing cap.
  - The retaining lugs of the connecting-rod bearing shells are always located on the same side in order to prevent the bearing shells from turning.
    
    Fig 5: Identifying Retaining Lugs
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  - The connecting-rod bearing cap and the connecting-rod big end have cast lugs which must lie above one another. These cast lugs lie on the same side as the twist lock (retaining lugs) of the connecting-rod bearing shells.
  - The cast lugs, twist lock (retaining lugs) and the flat side of the piston crown are on the same side.
    
    Fig 6: Identifying Connecting-Rod Bearing Cap And Piston
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  - The flat side of the piston crown always points to the centre of the cylinder block.
  - Refit pistons according to removal markings (if being reused).
  - If new connecting-rod bearing shells are used, there will be a red marking on the upper shell and a yellow marking on the lower shell.
9. 1.8. Assign connecting rod bearing caps correctly and screw in the connecting rod bolts -7- by hand. When doing so, make sure that the locking lugs on the bearing shells are aligned.
10. 1.9. Carefully tap the connecting rod bearing caps -6- with a plastic hammer until they are seated correctly so that the tightening torque will be accurate.
11. 1.10. Tighten all connecting rod bearing screws -7- to the specified tightening torque.
12. 1.11. Turn the crankshaft several times to check that it turns smoothly.
13. 1.12. Align the crankshaft so that the gap -arrow- on the drive plate for the inductive pickup is facing downwards (rough TDC presetting).
  Pfeil - Setting of gap on drive plate for inductive pickup (speed sender)
  
  Fig 7: Setting Of Drive Plate For Inductive Pickup
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.