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Home >> Porsche >> 2016 >> Cayman GTS, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 54 (13 - Engine - CRANKGEAR, Pistons) >> WM 131037 Disassembling And Assembling Pistons On 4.8-Litre DFI Engines (Cayenne Tip, Cayenne Man, Cayenne Diesel, Cayenne GTS Tip "PORSCHE Design Edition 3") >> Assembling Pistons

Assembling 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.

Information 

  1. Piston-ring set; oil with engine oil; TOP marking facing upwards; oil scraper ring down
  2. Piston; different on naturally aspirated and turbo engines; combustion chamber recess facing centre of engine; left and right different; direction of travel arrow in direction of travel
  3. Piston-pin circlip (positioned at 6 o'clock or 11 o'clock)
  4. Piston pin; oil
  5. Connecting rod
  6. Connecting rod bolt; replace as it must be tightened in the plastic area; oil screw
  7. Connecting rod bearing shells; oil with engine oil
    Fig 2: Locating Oil Applying Area On Connecting-Rod Assembly And Bearing Shells
    G09409096Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. View A (identification area for connecting-rod number; fit connecting rod with identification area facing exhaust side; markings on connecting rod and lid must be on the same side)
  2. View B (fit bearing shells flush and press in by hand)
  3. View C (fit bearing shells flush and press in by hand)
    Fig 3: Identifying Piston Classification
    G09409097Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Inspection stamp (supplier)
  2. Arrow marking in direction of travel
  3. Porsche short numeric code without main or middle number
  4. Cylinder bank identification
  5. Marking area for weight group
  6. Marking area for dimension group
  7. Barcode 128 (short numeric code (without main group) and weight group)
  8. Direction of travel arrow
  9. Short numeric code (supplier)
  1. First fit the two-piece oil scraper ring. To do this, insert the oil scraper spring into ring groove 3. Carefully force the oil scraper ring (TOP marking facing up towards the piston crown -A-  ) apart with your hand and fit it into the third piston ring groove above the oil scraper spring.
    Fig 4: Locating Piston Ring Marking
    G09409098Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. When fitted, the gap in the oil scraper ring must be offset by exactly 180° with respect to the gap in the oil scraper spring. Make sure that the oil scraper spring is in the middle of the oil scraper ring.
    CAUTION: Engine damage if piston rings overstretched!

    → Do not overstretch piston rings with piston ring pliers. Spread the piston ring until it just fits over the piston.

    Information 

    • The two compression rings have different strengths and can only be installed in the appropriate groove. 
    • If the piston ring has the inscription TOP, this must point to the piston crown. 
  3. Insert piston ring into the piston ring pliers. Make sure that, when installed, the marking on the piston rings is pointing in the direction of the piston crown -A-  . Spread the piston ring until it fits across the piston.
    Fig 5: Removing Piston Ring Using Piston Ring Pliers
    G09409099Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 6: Identifying Piston Ring Designation
    G09409100Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Fit piston rings. Using the piston ring pliers, insert the middle piston ring into the second ring groove in such a way that the inscription TOP is facing the piston crown. Insert the top piston ring into ring groove 1 in such a way that the inscription TOP is facing the piston crown.
  5. Check that the piston rings are correctly seated and positioned. Make sure that the oil scraper spring is inside the oil scraper ring. In the case of the piston ring in ring groove 2, the inscription TOP must point to the piston crown. The top piston ring must be installed in such a way that the inscription TOP is facing the piston crown. The gaps in the individual piston rings must always be offset by 120°.
  6. Fit a piston-pin circlip. To do this, insert the piston-pin circlip into the ring groove of the piston pin eye so that the ring gap is offset with respect to the piston crown (6 or 11 o'clock position). Press this end into the ring groove with your thumb -1-  .
    Fig 7: Inserting Piston-Pin Circlip Into Piston Pin Eye Ring Groove
    G09409101Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Lever the piston circlip into the ring groove using a small screwdriver while continuing to press it down.
    Fig 8: Inserting Piston Circlip Into Ring Groove Using Small Screwdriver
    G09409102Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. If the piston circlip does not slide into the ring groove right away, press the second gap end of the piston circlip into the ring groove. Ensure correct installation seating.
    Fig 9: Pressing Piston Circlip Into Ring Groove
    G09409103Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Secure piston with fitted piston-pin circlip facing downwards and connecting rod on retaining device 9597  .
    Fig 10: Securing Piston On Retaining Device 9597
    G09409104Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  10. Place piston pin and connecting rod in installation position. Ensure that the connecting rod marking is facing the exhaust side and the combustion chamber recess is facing the centre of the engine during assembly. Direction of travel arrow on the piston must be in direction of travel.
  11. Slide the oiled piston pin through the piston pin eye and through the connecting rod eye. Tap in carefully with a rubber hammer if necessary.
  12. Fit the second piston-pin circlip using the same procedure. Align the ring gap so that it is facing downwards, away from the piston crown (6 o'clock position, 11'o'clock position optional).
  13. Check connecting rod and piston for smooth operation.
  14. Fit connecting-rod bearing shells in connecting-rod big end and connecting-rod bearing cover. The retaining lugs must be positioned in the appropriate grooves and on the same side -B  and C-  . The matching numbers -A-  must be the same and must be on the same side (pointing to the exhaust side when installed). Tighten the connecting-rod bolts by hand and position the complete connecting rod ready for assembly.
    Fig 11: Identifying Connecting Rod Bearing Retaining Lugs
    G09409105Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 12: Identifying Connecting Rod Number Marking Surface
    G09409106Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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