Installing Pistons - Cylinders 4 To 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. Screw in screws -2-  on the crankshaft flange by hand.
2. Use > 9773 - turning device-1 -  to turn the crankshaft until the connecting rod bolts can be reached.

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   Turning crankshaft (without vibration damper)

3. Check that the new con-rod bearing shells are seated correctly (check retaining lugs) -Arrow-  .

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   Retaining lugs for connecting-rod bearings

4. 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)

   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. Install piston and connecting rod.

   During re-installation, insert the relevant piston into the related cylinder bore according to the marking.

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   Marking on piston in installation position (bank 4-6)

   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

   Coat pistons and tools with new engine oil.

   Insert piston as far as required into the assembly funnel 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 - Funnel
   3	Piston-pin circlip

   Guide connecting rod and piston -1-  into the cylinder bore and position funnel -2-  on the crankcase -Arrow-  .

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   Inserting piston into cylinder bore

   Hold the funnel -1-  securely and press the piston into the cylinder bore immediately using the handle of a hammer -2-  .

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   Pressing in piston

   Remove funnel -1-  .

6. Check that the piston is installed at the correct position.

   The arrows -4-  on new pistons must be facing the intake side. Or, used 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

7. Secure the correct connecting rod cap with new screws.
8. 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. 
9. Pre-fit connecting rods 1-3 with new bearings and the relevant connecting rod caps and new screws on the crankshaft.
10. Tighten new screws -1-  for connecting rod caps -2-  .

    Step 1: > Initial tightening 5 Nm (3.5 ftlb.) 

    Step 2: > Subsequent tightening torque 16 Nm (12 ftlb.) 

    Step 3: > Tightening torque 20 Nm (15 ftlb.) 

    Step 4: > Torque angle + 80° 

    Step 5: > Loosen screws - 360° 

    Step 6: > Initial tightening 5 Nm (3.5 ftlb.) 

    Step 7: > Subsequent tightening torque 16 Nm (12 ftlb.) 

    Step 8: > Tightening torque 20 Nm (15 ftlb.) 

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

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    Connecting rod cap screws

11. Fit rubber sleeves on connecting rods 1 to 3 to protect the cylinder lining > 9795 - Assembly aid  .
12. Remove > 9773 - turning device  for fitting the crankcase half for cylinders 1 to 3.