Removing Pistons - Cylinders 1-2

Information 

• The specified positions are for 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. 

Information 

• Some of the illustrations show the 6-cylinder engine variant as an example. 
• But this does not affect the procedure or the steps to be carried out. 

1. Mark pistons 1 and 2 -1-  in installation position.

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   Marking pistons

   Removing piston 1: 

2. Unscrew screw plug -1-  for removing piston pins.
   1. 2.1 Replace sealing ring.

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   Screw plug for removing piston pins/assembly (view of 991 crankcase, identical position)

   To remove a piston-pin circlip: 

3. Turn crankshaft to bottom dead center position of piston 1  .
   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 

   • Turn special tool only clockwise for removing the piston-pin circlips. 
   • Always hold the tool firmly with one hand when using it. 
   • Replace removed piston-pin circlips. 
4. Push special tool > 9764 - disassembly tool  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.

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   Groove for circlip hook (at approx. 9 o'clock position) when crankcase is positioned vertically

5. >9764 - Disassembly tool  must now be pushed into the circlip.
   1. 5.1 Carefully turn the tool to the left and right. You should feel resistance from the hook.

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   Positioning guide groove of tool 9764 in hook on circlip

6. Tighten circlip using tool 9764. To do this, turn the hexagonal handle clockwise -arrow-  until you feel a certain amount of resistance.

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   Pre-tensioning piston pin circlip

7. 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.

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   Tool 9764 at position A

   1. 7.1 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  .

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      Tool 9764 at position B

   2. 7.2 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.

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      Tool 9764 at stop ahead of position C

   3. 7.3 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.

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      Tool 9764 at position C

   4. 7.4 Slowly pull the tool with the circlip -1-  out of the crankcase -arrow-  . Dispose of old circlip.

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   Pulling tool 9764 out of the crankcase

   Pulling out piston pin: 

   > 9777 - Disassembly tool 

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   Tool 9777 for removing/fitting piston pins

   Interchangeable inserts for piston pins:

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   Tool 9777 with interchangeable inserts for various piston pins

   1. 53-mm insert for 2.0-liter engine
   2. Roll pin (must be screwed in securely)
   3. 56-mm insert for 2.5-liter engine
8. >9777 - Disassembly tool  must be pushed as far as it will go into the piston pin.
   1. 8.1 Hold the tool firmly at the front hexagon -1-  and turn the rear hexagon -2-  anti-clockwise as far as it will go -arrow-  .

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      Sliding tool 9777 into piston pin

   2. 8.2 Pull out the piston pin -1-  using the correct interchangeable insert -2-  . Inset shows the tensioned piston pin.

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      Removing piston pin

   3. 8.3 To loosen the piston pin, turn the rear hexagonal handle clockwise until the pin can be removed.
9. >9783 - Assembly aid  must be inserted into the cylinder bore from the oil pan side. Then press out the piston for cylinder 1  (by tapping lightly on the handle with the ball of your hand).
   1. 9.1 Assign the correct piston pin to the piston immediately.
   2. 9.2 To protect the cylinder liners on the connecting rod -1-  , fit an > 9795 - assembly aid-2-  (rubber sleeves).

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   Assembly aid (rubber sleeve) on connecting rod

   Removing piston 2: 

10. Remove cover -1-  on piston assembly on the transmission side.
    1. 10.1 Unscrew screw -2-  and pull off the cover.
    2. 10.2 Replace cover! 

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    Cover on piston assembly on transmission side

11. Turn crankshaft to bottom dead center position of piston 2  .

    The hook on the circlip must be at approx. 12 o'clock position when the cylinders are vertical -arrow-  !

    1. 11.1 Pull off piston-pin circlip -1-  on piston -2-  for cylinder 2.

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    Piston-pin circlip on piston for cylinder 2

    Information 

    • Turn special tool only clockwise for removing the piston-pin circlips. 
    • Always hold the tool firmly with one hand when using it. 
    • Replace removed piston-pin circlips. 
12. >9764/2 - Disassembly tool-1-  must now be pushed through the assembly bore -arrow-  .

    Used in the same way as the long disassembly tool on piston 1. 

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    Piston-pin circlip on piston 2

13. Use > 9777/2 - disassembly tool  to pull the piston pin and the relevant insert out of the piston.

    Used in the same way as the long disassembly tool on piston 1. 

14. >9783 - Assembly aid  must be inserted into the cylinder bore from the oil pan side. Then press out the piston for cylinder 2  (by tapping lightly on the handle with the ball of your hand).