Disassembling Pistons

Information 

• If reusing a piston, do not remove combustion residues on the piston crown are mechanically! 

Information 

• When disassembling the piston/connecting rod unit, note or mark the position, relationship to cylinder and installation position using a waterproof felt tip pen. 

Fig 1: Identifying Piston And Connecting Rod Components

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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

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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

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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. Secure piston on retaining device 9597  .
   Fig 4: Securing Piston On Retaining Device

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2. Remove both piston-pin circlips using a small screwdriver. To do this, guide the screwdriver through the small cutout and carefully lever out the piston-pin circlip.
   Fig 5: Removing Piston-Pin Circlips Using Small Screwdriver

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3. Insert piston into the retaining device 9597  (leave space below for the piston pins) and drive out piston pins using a suitable pressure piece.
   Fig 6: Removing Piston Pins Using Pressure Piece

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4. Remove connecting rod from the piston and place to one side.
   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.

5. Remove piston rings. Place the piston on a clean surface and look for the gaps in the piston rings.

   Information 

   • Compression rings and oil scraper rings are installed and removed differently. 
6. Remove the piston rings, starting at the piston crown. To do this, move the middle point of piston ring pliers, size 1 Nr.58  into the gap in the relevant ring. The holding arms of the piston ring pliers should clasp the piston ring from above. Only open the piston ring as much as is needed to remove the piston ring from the groove. Do not overstretch it!
   Fig 7: Removing Piston Ring Using Piston Ring Plier

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7. Relieve the piston ring pliers and remove the piston ring from the pliers.
8. Remove the two-piece oil scraper ring as follows: first, remove the outer ring by hand by carefully prising it away from the piston. Then remove the inner oil scraper spring in the same way.