Removing Pistons - Cylinders 3-4

Information 

• The parting surface between the connecting rod and connecting rod cap is broken during the manufacturing process. 
• Assign connecting rod cap to the relevant connecting rod immediately after removal. 
• Also check the four-digit matching number. 
• Replace connecting rod bolts. 
• Replace connecting rod bearings. 

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 3 and 4 in installation position.
2. Remove crankcase half 1-2.

   > 1001Z1 DISASSEMBLING ENGINE .

   1. 2.1 Unscrew upper fastening screw on the engine support.
3. Secure the crankshaft to the main bearing in the middle using special tool > 9779 - holding bridge-1-  .
   1. 3.1 Screw in and tighten two fastening screws -2-  hand-tight.

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   Holding bridge 9779 for crankshaft (view of 6-cylinder engine)

4. Screw in three screws -2-  for the vibration damper at the crankshaft flange.
   1. 4.1 Turn the crankshaft using special tool > 9773 - turning device-1-  so that the connecting rod bolts can be reached.

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   Turning the crankshaft (without vibration damper)

5. Remove pistons with connecting rods on cylinder bank 3-4.
   1. 5.1 Loosen and unscrew two screws -3-  on each connecting rod cap -1 and 2-  .
   2. 5.2 Replace connecting rod bolts! 

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   Connecting rod caps on cylinders 3 and 4

6. Remove pistons 3 and 4 with connecting rods.
   1. 6.1 On > 9783 - assembly aid-2-  , unscrew the grip handle and screw the bar into a threaded bore on the connecting rod -1-  . Press piston and connecting rod down out of the cylinder bore.
   2. 6.2 Repeat this step for piston 4.

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   Pressing out pistons and connecting rods

7. Remove connecting rods for cylinders 1-2 on the crankshaft.
   1. 7.1 Unscrew connecting rod bolts and remove connecting rod cap and connecting rod.
   2. 7.2 Replace screws.

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   Connecting rods 1 and 2

8. Replace connecting-rod bearing shells during assembly.
   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.

   Procedure for replacing pistons or connecting rods: 

9. Insert connecting rod with piston in special tool > 9778 - retaining device  .
   1. 9.1 Carefully remove piston-pin circlips with a small screwdriver.
   2. 9.2 Press out piston pin and set aside immediately with the relevant piston.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Piston/connecting rod in retaining device 9778

   1. Connecting rod with piston
   2. Retaining device