Installing turbocharger

Fit turbocharger. Insert a new seal between the turbocharger and the exhaust manifold and tighten the three fastening screws to 30 Nm (22 ftlb.).
Tighten exhaust manifold on the cylinder head. Position exhaust manifold with new seals (cylinder head and on the catalytic converter) on the cylinder head and insert in the exhaust catalytic converter at the same time. Position the nine fastening screws on the cylinder head by hand and tighten in two stages. First stage 25 Nm (18 ftlb.). Second stage 33 Nm (24 ftlb.).

Fig 1: Tightening Exhaust Manifold On Cylinder Head
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening occurs in two stages (first 25 Nm (18 ftlb.), then 33 Nm (24 ftlb.)) according to the sequence shown.

Fig 2: Identifying Tightening Sequence Of Exhaust Manifold Bolts
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Replace the four fastening nuts to the exhaust catalytic converter and tighten to 30 Nm (22 ftlb.).

Fig 3: Installing Fastening Nuts To Exhaust Catalytic Converter
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Tighten the two oil pipes to 30 Nm (22 ftlb.) each.

Fig 4: Tightening Two Oil Pipes
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Screw on the turbocharger support. Do not forget the washer beneath the new hexagon nut when doing this. Tighten the hexagon nut to 23 Nm (17 ftlb.). Then position the hexagon nut of the vent line by hand and tighten to 20 Nm (15 ftlb.).

Fig 5: Installing Turbocharger Support
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Install heat shield. Move heat shield into installation position again and tighten the two sheetmetal nuts.

Fig 6: Installing Heat Shield
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Push the pressure pipe back onto the turbocharger and tighten the hose clamp.

Fig 7: Tightening Pressure Pipe Hose Clamp
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Install charge air cooler. Insert the charge air cooler in the studs on the body. Tighten the rear fastening nut and the two fastening screws to 23 Nm (17 ftlb.).

Fig 8: Installing Charge Air Cooler
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Tighten the front fastening nut and the fastening screw to 23 Nm (17 ftlb.).
Tighten the two sheetmetal nuts on the heat shield.

Fig 9: Tightening Sheetmetal Nuts On Heat Shield
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Reconnect the two hose connections. Make sure that the clips are properly inserted when doing this. Press in the hose support until it is heard to engage.

Carry out oil level and tightness test.

NOTE: Conclude by carrying out oil level and tightness test.

TIGHTENING TORQUE SPECIFICATIONS - TURBOCHARGER

Location	Thread	Tightening torque Nm (ftlb.)
Turbocharger on the exhaust manifold	M8	23 (17 ftlb.)
Exhaust manifold on the cylinder head
- 1. stage		25 (19 ftlb.)
- 2. stage		33 (24.5 ftlb.)
Turbocharger on the exhaust catalytic converter	M8	30 (22 ftlb.)
Oil inlet line	M16 x 1.5	30 (22 ftlb.)
Oil return line	M16 x 1.5	30 (22 ftlb.)
Turbocharger support	M8	23 (17 ftlb.)
Oil inlet line on the turbocharger		20 (15.0 ftlb.)
Fastening screws on charge air cooler	M8	23 (17 ftlb.)