Removing Pistons - Cylinders 1-3

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Information

The specified positions relate to removing and installing components on the engine assembly support with the engine in a vertical position.
Mark pistons in installation position using a water-resistant marker.

Unscrew screw plug (M30 x 1.5) -1- for removing piston pins.
1. 1.1. Replace sealing ring.
  
  Fig 1: Identifying Piston Pins Screw Plug
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  To remove a piston-pin circlip:
Turn the crankshaft and vibration damper to the bottom dead center position -U 1/4 marking- and lock at this position using locating pin 9595/1 -1- .

Fig 2: Identifying Vibration Damper Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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.

Information
- Special tool disassembly tool 9764 for removing piston-pin circlips must only be turned in a clockwise direction.
- Always hold the tool firmly with one hand when using it.
- Replace removed piston-pin circlips.
Slide special tool disassembly tool 9764 through the assembly bore. The groove -arrow- for the hook on the circlip must be at 9 o'clock position when the engine is positioned vertically.

Fig 3: Cutting Circlip Hook Groove
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Disassembly tool 9764 must now be pushed into the circlip.
1. 4.1. Carefully turn the tool to the left and right. You should feel resistance from the hook.
  
  Fig 4: Positioning (Tool 9764) Guide Groove
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tighten circlip using tool 9764. To do this, turn the hexagonal handle clockwise -arrow- until you feel a certain amount of resistance.

Fig 5: Tightening Circlip Using Tool (9764)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Keep the hexagonal handle -1- tight and turn the pipe -3- clockwise until you feel a certain amount of resistance. The cheese head bolt -2- will move horizontally to the left from position A in the guide groove.

Fig 6: Turning Pipe Using Tool (9764) Position A
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 6.1. Hold the tool firmly at the pipe and keep it pressed slightly against the piston in a clockwise direction -arrow 2- . Slowly turn the hexagonal handle -1- until the cheese head bolt is at position B .
  
  Fig 7: Turning Pipe Using Tool (9764) Position B
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 6.2. Hold the hexagonal handle -1- firmly and turn the pipe clockwise -arrow 2- until you feel a certain amount of resistance. The cheese head bolt will move horizontally to the left from position B in the guide groove.
  
  Fig 8: Turning Pipe Using Tool (9764) Position C
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 6.3. Hold the tool firmly at the pipe and press it slightly against the piston. Slowly turn the hexagonal handle using spring force until the cheese head bolt is at position C . The circlip engages in the tool with an audible click.
  
  Fig 9: Holding Tool (9764) Position C
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 6.4. Slowly pull the tool with the circlip -1- out of the crankcase -arrow- . Dispose of old circlip.
  
  Fig 10: Pulling Tool 9764 Out Of Crankcase With Circlip
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  To remove a piston pin:
  
  Disassembly tool 9777
  
  Fig 11: Identifying Piston Pins Tool 9777
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Interchangeable inserts for piston pins:
  1. 53-mm insert for 2.7-litre engine
  2. Roll pin (must be screwed in securely)
  3. 56-mm insert for 3.4-litre and 3.8-litre engine
    
    Fig 12: Identifying Tool 9777 With Inserts
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Disassembly tool 9777 must be pushed as far as it will go into the piston pin.
1. 7.1. Hold the tool firmly at the front hexagon -1- and turn the rear hexagon -2- anti-clockwise as far as it will go -arrow- .
  
  Fig 13: Sliding Tool 9777 Into Piston Pin
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 7.2. Pull out the piston pin -1- using the correct interchangeable insert -2- . Inset shows the tensioned piston pin.
  
  Fig 14: Removing Piston Pin
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 7.3. To loosen the piston pin, turn the rear hexagonal handle clockwise until the pin can be removed.
  To remove a piston:
Assembly aid 9783 must be inserted into the cylinder bore from the oil pan side. Then press out the piston (by tapping lightly on the handle with the ball of your hand).
1. 8.1. Assign the correct piston pin to the piston immediately.
2. 8.2. Fit assembly aid 9795 -1- (rubber sleeves) on the connecting rod to protect the cylinder liner.
  
  Fig 15: Identifying Connecting Rods Protective Sleeves (9795)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Turn the crankshaft to the bottom dead center position U 2/5 marking at the vibration damper and lock at this position using a locating pin (tool 9595/1) -1- .

Fig 16: Identifying Vibration Damper Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 9.1. Repeat steps 3 to 8 for removing piston 2.
Turn the crankshaft to the bottom dead center position U 3/6 marking at the vibration damper and lock at this position using a locating pin (tool 9595/1) -1- .

Fig 17: Identifying Vibration Damper Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 10.1. Repeat steps 3 to 8 for removing piston 3.
Check piston wear during re-installation.
→ WM 131001 PISTON WEAR, WEIGHT GROUPS AND IDENTIFICATION MARKINGS .