Fitting Pistons and Connecting Rods Cylinders 1 - 3

Removing and installing pistons - Boxster S

Engine type M96/21







Tools

Fitting pistons and piston rods in the crankcase half or bearing housing of cylinder bank 1 - 3

Installation





1. Fasten crankcase half, cylinders 1 - 3, in conjunction with mounting elements 9590 to engine holder 9589.





2. Clean bearing housing support surface, particularly in area of oil duct. Check dowel sleeves for correct seating.

3. Installation of the complete bearing housing in the crankcase half, cylinders 1 - 3.
As the bearing housing is heavy, it should be installed using a workshop crane.








Carefully and in stages, lower bearing housing with fitted holder 9607 and using a workshop crane towards the dowel sleeves (2 ea.), observing the following points:





3.1 To aid in guiding, screw pan head screws approx. 3 turns into the bearing housing from below.








3.2 Just before reaching the final installation position, pull the loosened intermediate-shaft flange out of the housing area and rotate the flange so that the two flange lugs that are spaced closest together face upwards.





3.3 After lowering, check whether there is sag in the upper chain area or sufficient lever travel exists. Lift the bearing housing and check the chain installation if necessary.

3.4 Remove two cap head screws (guidance aid).





4. For the following assembly procedure piston installation, cylinders 1, 2 and 3 the crankcase half and bearing housing unit must be held by at least two screw connections.
For this purpose, fasten two original cylinder head screws and plastic spacer sleeves, special tool 9613, from below.
Tightening torque 30 Nm (22 ft. lbs.). Use Torx screwdriver insert T50 or T55.

5. Turn crankcase by 180' on the assembly support. Cylinders 1, 2 and 3 face upwards.

6. Fit belt pulley. Screw in fastening screw by hand.





7. Turn crankshaft clockwise until the bore U4 on the pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.





8. Remove preassembled connecting rod with piston of cylinder 1 from the assembly fixture.

9. Align the gaps of the upper piston rings offset by 180°.





10. Tighten piston ring clamp and fit piston in the cylinder bore with connecting rod.





11. Place piston with connecting rod in installation position.








Note Generously coat the piston and clamp with engine oil before fitting the piston.

12. Use the handle of a hammer to tap the piston into the cylinder while firmly pressing on the edge of the clamp. Use protective gloves.

Note The piston must be fitted in the cylinder carefully and with feeling. If the resistance increases, immediately interrupt the assembly process. Reposition the piston ring clamp and repeat the assembly operation.





13. Centre the piston in the cylinder bore and carefully push it down with the assembly aid (special tool 9598).





14. Turn crankcase by 180°. Make sure the bearing shell is correctly seated in the connecting rod. The fixing lugs point to the oil pan.








15. Fit end caps. Lubricate bearing shells. The recesses of the connecting-rod bearing twist lock must face each other.

16. Tightening specification:

Oil thread and contact surface.

1. Initial tightening 20 Nm (15 ft. lbs.)

To facilitate subsequent checks it is recommended that the screw heads be marked with a colored pen after initial tightening.

2. Final tightening 1 x 90° turn

Use 10 mm socket wrench insert (double hexagon).

17. Fitting piston and connecting rod in cylinder 2





Turn crankcase by 180°. Turn crankshaft clockwise until the bore U5 on the pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.

18. Prepare preassembled connecting rod of cylinder 2 for installation. Perform the following assembly steps as described from Step 8 to Step 16.

19. Fitting piston and connecting rod in cylinder 3





Rotate crankshaft clockwise until bore U6 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.

20. Prepare preassembled connecting rod of cylinder 3 for installation. Perform the following assembly steps as described from Step 8 to Step 16.

Note Leave crankshaft at position U6 after fitting the piston and connecting rod in cylinder 3. This position is necessary for subsequent fitting of the piston of cylinder 6.

21. Remove belt pulley.