Removing and installing oil pump for turbocharger: Installation

Grease oil pump gears and contact surfaces with Optipitt assembly grease. Make sure that grease does not enter the receiving bores for the dowel pins.
Insert oil pump gears in the housing. The all-round groove of the outer oil pump gears must face the oil pump cover.

Fig 1: Inserting Oil Pump Gears In Housing
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Fasten oil pump cover. When tightening, simultaneously check the operating smoothness of the oil pump. Tighten the screws crosswise to 10 Nm (7.5 ftlb.).

Fig 2: Fastening Oil Pump Cover
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Tightening torque 10 Nm (7.5 ftlb.).
Prepare bracket for installation. Unscrew plug (Torx T30).

Fig 3: Removing Oil Pump Plug
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Fit new O-ring on the oil pump cover and new O-rings on the lower coolant connection flanges. Apply a thin coat of Vaseline on the O-rings.
Position bracket on the crankcase and simultaneously use a screwdriver to connect the oil pump drive shaft and the intermediate shaft. Do not use excessive force; gently press in place by hand.

Fig 4: Connecting Oil Pump Drive Shaft And Intermediate Shaft
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Provisionally fasten the bracket using an auxiliary screw. The auxiliary screw can be removed again once the oil lines and coolant hoses have been fastened.

Fig 5: Removing Auxiliary Screw
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NOTE: Otherwise, the bracket is held only by the O-rings.
Apply Loctite 574 on the thread of the plug and fasten the plug.

Fig 6: Fastening Plug
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Tightening torque 4 Nm (3.0 ftlb.).
Fit oil lines for the right-hand side. Use new O-rings.

Fig 7: Installing Oil Lines For Right-Hand Side
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Fit oil lines for the left-hand side. Use new O-rings.

Fig 8: Installing Oil Lines For Left-Hand Side
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Fit coolant lines over the coolant pump. Use water or coolant to facilitate fitting.

Fig 9: Installing Coolant Lines Over Coolant Pump
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NOTE: If incorrectly positioned, the generator bracket would make contact and cause leaks.
Remove auxiliary screw.

Fig 10: Removing Auxiliary Screw
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Fasten engine carrier.

Fig 11: Fastening Engine Carrier
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Tightening torque 65 Nm (48 ftlb.).
Fasten engine carrier on the engine mounts (wrench size 18).
Tightening torque: 85 Nm (63 ftlb.).
Remove special tool (retaining device) 9624/1.

Fig 12: Removing Special Tool (Retaining Device) 9624/1
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Fasten stabilizer.
Install rear mufflers with new seals. The seals between the exhaust turbochargers and the rear muffler must be replaced. Move the rear muffler into installation position and push the two tensioning straps over the holder on the engine carrier. Subsequently tighten the two hexagon socket head bolts slightly.

Fig 13: Installing Rear Mufflers With Seals
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Push the heat shields over the studs of the exhaust turbocharger. Fit new hexagon nuts.

Fig 14: Installing Turbocharger Nuts
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Tightening torque 30 Nm (22 ftlb.).
Tighten restraining straps on the rear muffler.
Tightening torque 15 Nm (11.0 ftlb.).
Fit heat shields, bumper and rear spoiler.
Install bracket for the generator. Replace the four O-rings on the two connecting flanges between the two coolant outlet necks of cylinder bank 1-3. Then screw in the four fastening screws. Important: The front right screw must be inserted with Loctite 574 (as shown in Fig 15 ).

Fig 15: Installing Front Right Screw - Gererator Bracket
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Tightening torque 65 Nm (48 ftlb.).
Check whether locking clips are properly seated.

Fig 16: Identifying Properly Seated Locking Clips For Coolant Hoses
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Fit coolant hoses. Always replace O-rings on the coolant hoses. Wet O-rings with plenty of water.
NOTE: Never fit dry; only use water.
Push on coolant hose. Align the flange of the coolant hose as shown in Fig 17 (lug/groove). Press the coolant hose firmly against the connection neck. The coolant hose must engage audibly. Then recheck whether it is fitted properly by tilting and pulling on it.

Fig 17: Aligning Flange Of Coolant Hose
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Fit air-conditioning compressor. Do not forget the spacer sleeve.
Install throttle body.
Install generator.
Install hydraulic pump.
Fit drive belt (see REMOVING AND INSTALLING DRIVE BELT (ENGINE INSTALLED) ).
Install air cleaner assembly.
Bleed the cooling system. Use the Porsche System Tester 2 for this purpose. Select the "Special functions" menu
Bleed the steering system. See BLEEDING THE STEERING SYSTEM .
Bring the engine to operating temperature and check it for leaks.