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Home >> Porsche >> 2019 >> 718 Boxster Base, Automatic DCT Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (13 Engine - Crank Drive, Pistons 2.5L -- 982 - BOXSTER/CAYMAN) >> WM, 131020 - Removing And Installing Pistons >> Installing Pistons >> Installing Pistons For Cylinders 1-2

Installing Pistons For Cylinders 1-2

WARNING: This page is about a different variant/trim than selected.
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 

  1. Assemble the crankcase.

    > 1001Z2 ASSEMBLING ENGINE .

  2. Screw in two M8 screws on the crankshaft flange.
  3. Turn con-rod journal for cylinder 2 to assembly position at bottom dead center.
  4. Pull off the boot on the connecting rod, set it in a vertical position and secure in place from transmission side using > 9782/1 - centring mandrel  .
    1. 4.1 Guide centring mandrel with the correct diameter into the assembly bore.
      G14944576Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Guiding centring mandrel into assembly bore

    2. 4.2 Centre the connecting rod in the small connecting-rod eye -1-  using the centring mandrel -2-  .
    G14944577Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Centring the connecting rod using tool 9782

  5. Install pistons for cylinders 1 and 2.
    1. 5.1 For re-installation, fit the relevant piston into the related cylinder bore according to the inscription.
    2. 5.2 Align piston rings. Offset the ring gaps by 120°. Check the twist lock -arrow-  at the second ring groove.
      G14944578Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Twist lock on second piston ring

    3. 5.3 Check installation position of pistons. Data matrix code is facing the intake side.
      G14944579Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Markings on pistons

      G14944580Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Markings on pistons (example)

      1. Pistons
      2. Data matrix code
      3. Porsche part number
      4. Dimensional group (only dimensional group X available as replacement)
      5. Manufacturer's logo
      6. Weight group
      7. Installation position: On new pistons, the arrow must be facing the intake side
    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.
      G14944581Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Lower edge of piston flush with surface of assembly funnel

      1. Pistons
      2. >9784 - Funnel  (3.4-liter) or > 9784/3 - funnel  (2.7-liter)
      3. Piston-pin circlip
    6. 5.6 Guide the piston into the cylinder bore and carefully position the funnel on the crankcase.
      G14944582Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Inserting piston into cylinder bore (shown on 6-cylinder engine)

    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.
      G14944583Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Pressing in piston (shown on 6-cylinder engine)

    8. 5.8 Remove assembly funnel.
  6. Position the piston.
    1. 6.1 Tools for 2.0-liter pistons:  > 9787/4 - Piston assembly aid  and handle of > 9598 - assembly aid  .
    2. 6.2 Tools for 2.5-liter pistons:  > 9787/5 - Piston assembly aid  and handle of > 9598 - assembly aid  .
    3. 6.3 Use the relevant assembly aid -1-  to press the piston into the cylinder bore as far as the contact surface of the > 9782 - centring mandrel-2-  .
    4. 6.4 Pull out the centring mandrel and press the piston down at the same time until the assembly aid is positioned correctly.
    G14944584Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Positioning piston in the cylinder using assembly aid (shown on 6-cylinder engine)

  7. Fix piston and connecting rod in place using > 9782 - centring mandrel  .
    G14944585Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Centring piston with connecting rod (view of belt side)

  8. Fit the piston pin.
    1. 8.1 Coat the piston pin with new engine oil and slide it onto the > 9777 - disassembly tool  .
    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-  ).
      G14944586Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Securing piston pin on tool 9777

    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.
      G14944587Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Fitting piston pin

    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.
      G14944588Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Tapping in piston pin using tool

    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. 
  9. Insert new piston-pin circlip into > 9776 - assembly tool  .
    1. 9.1 Once installed correctly, the large hook -1-  on the circlip must be at approx. 9 o'clock  position (when engine is vertical).
      G14944589Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Large circlip hook at 9 o'clock position (engine vertical)

    2. 9.2 Turn the groove for the small hook on the tool -2-  towards the observer.
      G14944590Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Pressing piston-pin circlip into tool 9776

    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.
      G14944591Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Small hook facing groove

      View of turning circlip:

      G14944592Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Turning piston-pin circlip in tool

    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 assembly position -arrow-  . You should hear a distinct click.
    G14944593Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Pressing circlip into assembly position

  10. Fit the piston-pin circlip on the piston.
    1. 10.1 Check the position of the piston-pin circlip -1-  again.
      G14944594Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      View of circlip in tool 9776 in front of assembly bore

    2. 10.2 > 9776 - Assembly tool-1-  must now be guided into the assembly bore -arrow-  .
      G14944595Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Guiding tool 9776 into assembly bore

    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.
      G14944596Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Small hook at 11 o'clock position

    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.
      G14944597Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Tool tube 9776

    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 > 9776 - Assembly tool  must now be removed.
    7. 10.7 Check that the piston-pin circlip is seated correctly using a torch. The correct assembly position is clearly visible.
  11. Turn con-rod journal for cylinder 2 to assembly position at bottom dead center.
    1. 11.1 Repeat Steps 4 - 10  for cylinder 2 using the "short" tools on the transmission side.
    2. 11.2 Check the position of the circlip -arrow-  via the housing bore on the transmission side.
    G14944598Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Piston-pin circlip on piston for cylinder 2

  12. Fit screw plug for fitting piston pin with a new sealing ring on the belt side.

    > Tightening torque 80 Nm (59 ftlb.) 

    Information 

    • Install the cover for the bore for fitting piston pins on the transmission side (pistons 2 and 4) until it is flush with the surface of the housing. 
    • When fitting the cover, make sure that the bore is aligned with the screw thread! Do not turn the cover. 
  13. Fit new cover -1-  on the transmission side using a screw -2-  . Check position!
    1. 13.1 Carefully tap in the cover as far as it will go using a suitable socket (a/f 20) or pressure piece with an external diameter of 24 mm.

      There must be no gap between the sheetmetal edge of the cover and the sealing face! -Arrows- 

    2. 13.2 Fit and tighten screw.

      > Tightening torque 13 Nm (9.5 ftlb.) 

    G14944599Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Cover for piston pin bore on transmission side

  14. Complete the engine.

    > 1001Z2 ASSEMBLING ENGINE .

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