Installing Pistons - Cylinders 4-6

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. 

1. Turn crankshaft into position.

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   Turning crankshaft (without vibration damper)

   1. 1.1  Screw in screws -2-  by hand.
   2. 1.2  Fit > 9773 - turning device-1-  and turn the crankshaft so that connecting-rod bearing covers are accessible.
2. Check that the retaining lugs -Arrow-  are seated correctly.

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   Retaining lugs for connecting-rod bearings

3. Check allocation of connecting rod to connecting rod cap (matching number -1-  and data matrix code).

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   Connecting rod on crankshaft (marking)

4. Install pistons -4 to 6-  with connecting rod.
   1. 4.1  Insert pistons -4 to 6-  into the relevant cylinder bore according to the inscription.

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      Marking on pistons in installation position

   2. 4.2  Align piston rings and re-position ring gaps by 120°. Check twist lock -Arrow-  on the second ring groove.

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      Twist lock on second piston ring

   3. 4.3  Coat pistons and tools with new engine oil.
   4. 4.4  Insert piston -1-  as far as required into the > 9784/2 - funnel-2-  until the lower edge of the piston is flush with the surface of the tool.

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      Lower edge of piston flush with contact surface of assembly funnel

      1	Piston
      2	> 9784/2 - Funnel
      3	Piston-pin circlip

      Information 

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

      Information 

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      Markings on connecting rods and pistons

      • Check installation position of pistons. 
      • The matching number -2- and data matrix code -inset- on the correctly installed connecting rod must be facing the exhaust side. 
      • The data matrix code -1- on the piston must be facing the intake side. 
   5. 4.5  Guide connecting rod and piston -1-  into the cylinder bore and position > 9784/2 - funnel-2-  on the crankcase -Arrow-  .

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      Piston in cylinder bore

   6. 4.6  Hold the > 9784/2 - funnel-1-  securely and press the piston into the cylinder bore using the handle of a hammer -2-  .

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      Piston

   7. 4.7  Remove > 9784/2 - funnel-1-  .
5. Check that the piston is installed at the correct position.
   1. 5.1  The arrows -4-  on new pistons must be facing the intake side.
   2. 5.2  In the case of re-installed pistons, the data matrix code -1-  and the larger valve recesses -3-  must be facing the intake side.

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   Marking on pistons

   1	Data matrix code
   2	Classification letter for piston assembly
   3	Valve recesses on intake valves (larger)
   4	Arrow must be facing the intake side on new pistons; centered or side position.
   5	Manufacturer's logo
   6	Dimensional group (only dimensional group X available as replacement)
   7	Valve recesses on outlet valves
   8	Porsche part number
   9	Weight group

6. Secure the correct connecting rod cap with new screws.
7. Repeat these steps for pistons 5 and 6.

   Information 

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   Connecting rod on crankshaft

   • The matching number -1- and data matrix code are facing the exhaust side. 
8. Pre-fit connecting rods 1 to 3 with new bearings and the relevant connecting rod caps and new screws on the crankshaft.
9. Tighten new screws -1-  for connecting rod caps -2-  .

   Step 1: > Initial tightening 5 N.m (3.5 ft lb.) 

   Step 2: > Subsequent tightening torque 16 N.m (12 ft lb.) 

   Step 3: > Tightening torque 20 N.m (15 ft lb.) 

   Step 4: > Torque angle + 80° 

   Step 5: > Loosen screws - 360° 

   Step 6: > Initial tightening 5 N.m (3.5 ft lb.) 

   Step 7: > Subsequent tightening torque 16 N.m (12 ft lb.) 

   Step 8: > Tightening torque 20 N.m (15 ft lb.) 

   Step 9: > Torque angle + 80° +/- 3° 

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   Connecting rod cap screws

10. To protect the cylinder linings, fit connecting rods 1 to 3 using > 9795 - assembly aid  .
11. Remove > 9773 - turning device  .