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

The connecting-rod bolts must be replaced!

Fit the oil scraper ring.
1. 1.1. Carefully open up the oil scraper ring with your hand and insert it into the groove.
2. 1.2. Fit the second ring over the oil scraper spring in the same way.
3. 1.3. The gap in the oil scraper ring must be offset by exactly 180° with respect to the gap in the oil scraper spring when fitted. Make sure that the oil scraper spring is centred in the oil scraper ring.
NOTE:
Incorrect handling of piston rings
- Risk of strain and damage to piston rings
→ Only open up the piston ring using the piston ring pliers sufficiently to allow you to remove or fit it.

→ Do not use force to install pistons.
NOTE:
Incorrect handling of piston rings
- Risk of strain and damage to piston rings
→ Only open up the piston ring using the piston ring pliers sufficiently to allow you to remove or fit it.

→ Do not use force to install pistons.
Fit piston rings.

Fig 1: Locating Top Marking On Piston Ring
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information
- The TOP marking must always face the piston crown.
1. 2.1. Observe the Top marking.
2. 2.2. Insert piston ring into the piston ring pliers.
3. 2.3. First fit the bottom piston ring.
4. 2.4. Then insert the top piston ring into the groove.
5. 2.5. The gaps in the individual piston rings must always be offset by 120° .
Fit the piston pin.
1. 3.1. Insert piston in retaining device 9597 .
  Information
  - If piston is sluggish, heat to 60 °C and remove and install with mandrel.
2. 3.2. Press the piston-pin circlip into the ring groove with your thumbs.
  
  Fig 2: Pressing Piston-Pin Circlip Into Ring Groove
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Information
  - The gap of the piston ring may not be located next to the removal recess.
3. 3.3. Offset the ring gap in the piston-pin circlips by 30° with respect to the cut-out.
4. 3.4. Insert piston-pin circlip.
  
  Fig 3: Fitting Piston-Pin Circlip
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Lever the piston-pin circlip into the ring groove using a small screwdriver.
  
  Fig 4: Levering Piston-Pin Circlip Into Ring Groove Using Small Screwdriver
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 3.5. Place piston pin and connecting rod in installation position.
  
  Fig 5: Inserting Piston Pin And Connecting Rod In Retaining Device 9597
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. 3.6. The cast lugs on the connecting rod and connecting rod big end -1- must be on the narrow side of the piston -2- .
  
  Fig 6: Locating Marking On Connecting Rod And Connecting Rod Big End Cast Lugs
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Information
  - If piston is sluggish, heat to 60 °C and remove and install with mandrel.
7. 3.7. Insert the oiled piston pin through the piston and connecting-rod eye as far as the circlip using a plastic hammer and pressure piece.
  
  Fig 7: Inserting Oiled Piston Pin Using Plastic Hammer And Pressure Piece
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit the second piston-pin circlip in the same way.