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)

   Screw in screws -2-  by hand.

   > 9773 - Fit 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.

   Insert pistons -4 to 6-  into the relevant cylinder bore according to the inscription.

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   Marking on pistons in installation position

   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 -1-  as far as required into the > 9784/2 - assembly 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. 

     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

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

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     Piston

     > 9784/2 - Remove funnel-1-  .

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

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

   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 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; centred 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 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

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