Installing Pistons For Cylinders 1-3

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Information

If pistons are to be replaced, only one weight group is permitted for all pistons.

Assemble the crankcase.
→ 1001Z2 ASSEMBLING ENGINE .
Secure the vibration damper to the crankshaft flange with two M8 screws.
Turn con-rod journal for cylinder 3 to installation position.
1. 3.1. To do this, use turning device 9773 to turn the crankshaft to the bottom dead center position U 3/6 at the vibration damper.
  
  Fig 1: Identifying Vibration Damper Marking
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Pull off the boot on the connecting rod, set it in a vertical position and secure in place using centering mandrel 9782 .
1. 4.1. Guide centering mandrel with the correct diameter into the assembly bore.
  
  Fig 2: Installing Centering Mandrel Into Assembly Bore
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 4.2. Center the connecting rod in the small connecting-rod eye -1- using the centering mandrel -2- .
  
  Fig 3: Adjusting Connecting Rod Using Tool 9782
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install pistons for cylinders 1-3.
1. 5.1. For re-installation, fit the relevant piston into the related cylinder bore according to the inscription. Start with piston 3.
  
  Fig 4: Identifying Pistons Marking
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 5.2. Align piston rings. Offset the ring gaps by 120°. Check the twist lock -arrow- at the second ring groove.
  
  Fig 5: Locating Second Piston Ring Lock
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 5.3. Check installation position of pistons. Cone-shaped neck and data matrix code on the piston must be facing the intake side.
  1. Piston
  2. Data matrix code on piston
  3. Porsche part number
  4. Dimensional group (only dimensional group X available as replacement)
  5. Manufacturer's logo
  6. Weight group
    
    Fig 6: Locating Piston Markings
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 5.4. Coat pistons and tools with new engine oil.
5. 5.5. Insert the piston as far as required into the assembly sleeve until the lower edge of the piston is flush with the surface of the sleeve.
  1. Piston
  2. Funnel 9784 (3.4-litre) or funnel 9784/2 (3.8-litre)
  3. Piston-pin circlip
    
    Fig 7: Inserting Piston Into Assembly Funnel
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. 5.6. Guide the piston into the cylinder bore and carefully position the funnel on the crankcase.
  
  Fig 8: Inserting Piston Into Cylinder Bore
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. 5.7. Press the piston into the cylinder bore immediately using the handle of a hammer -2- and hold assembly funnel -1- firmly while doing this.
  
  Fig 9: Pressing Piston Into Cylinder Bore
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. 5.8. Remove assembly funnel.
Position the piston.
1. 6.1. Piston assembly aid 9787 or piston assembly aid 9787/1 must now be screwed to the handle of the assembly aid 9598 .
2. 6.2. Use the relevant assembly aid to press the piston into the cylinder bore as far as the contact surface of the centering mandrel 9782 -2- .
3. 6.3. Pull out the centering mandrel and press the piston down at the same time until the assembly aid is positioned correctly.
  
  Fig 10: Positioning Piston In Cylinder Using Assembly Aid
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fix piston and connecting rod in place using centering mandrel 9782 .

Fig 11: Adjusting Piston And Connecting Rod
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit the piston pin.
1. 8.1. Coat the piston pin with new engine oil and slide it onto the disassembly tool 9777 .
2. 8.2. Secure the tool at the front hexagon -1- and turn it anti-clockwise as far as it will go at the rear hexagon -2- (-arrow- ).
3. 8.3. Slide the piston pin into the piston/connecting-rod eye. Guide the piston pin -1- using the tool -2- until it goes past the edge of the cylinder -arrow- to the piston.
  
  Fig 13: Installing Piston Pin
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 8.4. Tap the tool lightly with the ball of your hand, if necessary, while holding the tool firmly in place -1- . Insert pin as far as it will go.
  
  Fig 14: Tapping Piston Pin Using Tool
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 8.5. Turn the tool at the rear hexagon in clockwise direction until it pulls easily out of the piston pin without resistance.
  Information
  - Always replace piston-pin circlips following removal.
Insert new piston-pin circlip into assembly tool 9776 .
1. 9.1. The large hook -1- on the circlip will have to be at approx. 9 o'clock position later (when engine is vertical).
  
  Fig 15: Identifying Circlip Hook (Engine Vertical)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 9.2. Turn the groove for the small hook on the tool -2- towards the observer.
  
  Fig 16: Pressing Piston-Pin Circlip Into Tool 9776
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 9.3. Slide a new circlip into the assembly tool and press the edges together.
4. 9.4. Position the small hook towards the groove -arrow- . Turn the circlip slightly if necessary.
  
  Fig 17: Locating Hook Groove
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Turn the circlip as required.
  
  Fig 18: Turning Piston-Pin Circlip In Tool
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 9.5. Pull back and hold push rod in tool. Place the pipe -1- on a hard surface. Slowly guide the push rod down and press the circlip into installation position -arrow- . You should hear a distinct click.
  
  Fig 19: Pressing Circlip Into Installation Position
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit the piston-pin circlip on the piston.
1. 10.1. Check the position of the piston-pin circlip -1- again.
  
  Fig 20: Identifying Piston-Pin Circlip
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 10.2. Assembly tool 9776 -1- must now be guided into the assembly bore -arrow- .
  
  Fig 21: Pressing Tool 9776 Into Assembly Bore
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 10.3. Position the tool with the small hook at approx. 11 o'clock position -arrow- and place it in the assembly groove on the piston.
  
  Fig 22: Positioning Tool With Hook
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 10.4. Carefully turn the tube of the tool to the left and right -arrows- while pressing slightly against the piston at the same time. You should feel a certain amount of resistance in the half-moon-shaped bore on the piston at both sides.
  
  Fig 23: Turning Tool Tube (9776)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 10.5. Press the tube of the tool against the piston and hold it firmly in place. Then, tap the push rod slightly towards the piston with the ball of your hand. The circlip will lock with a clearly audible click.
6. 10.6. Assembly tool 9776 must now be removed.
7. 10.7. Check that the piston-pin circlip -2- is seated correctly over cylinder bore 2 using a mirror -1- and a torch. The correct assembly position is clearly visible.
  
  Fig 24: Checking Position Of Piston-Pin Circlip Using Mirror
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Turn con-rod journal for cylinder 2 to installation position.
1. 11.1. To do this, use turning device 9773 to turn the crankshaft to the bottom dead center position U 2/5 at the vibration damper.
  
  Fig 25: Identifying Vibration Damper Marking
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 11.2. Repeat steps 4 - 10 for cylinder 2. Check the position of the circlip over cylinder bore 1.
Turn con-rod journal for cylinder 1 to installation position.
1. 12.1. To do this, use turning device 9773 to turn the crankshaft to the bottom dead center position U 1/4 at the vibration damper.
  
  Fig 26: Identifying Vibration Damper Marking
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 12.2. Repeat steps 4 - 10 for cylinder 1.
3. 12.3. The position of the circlip can be checked on cylinder 1 through the assembly bore. The large hook must be at 9 o'clock position when the engine is vertical.
  
  Fig 27: Identifying Piston Circlip Installation Position
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit screw plug (M30 x 1.5) for fitting piston pin with a new sealing ring.
Complete the engine.
→ 1001Z2 ASSEMBLING ENGINE .