Installing Turbocharger For Cylinder 4-6

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

→ Close off all openings immediately after exposing them (with adhesive tape, suitable stoppers).

1. Pull off stoppers on oil and coolant lines one after the other, collect residual fluid and then re-insert the stoppers.
2. Fit new seal on the turbocharger/exhaust manifold flange, insert turbocharger and fix in place on the flange using three new M8 lock nuts.
3. Screw in Torx screw (M8 x 16) on turbocharger holder.

   Information 

   • Replace O-rings. 
   • Grease O-rings with a light coating of Kluber Syntheso Glep (Part No.: 000.043.204.68). 
4. Fit oil and coolant lines with new O-rings on the turbocharger.

   → WM 217119 REMOVING AND INSTALLING OIL PRESSURE LINE FOR TURBOCHARGER (GT2 RS) .

   1. 4.1. Oil and coolant lines on turbocharger:

      → Tightening torque: 10 Nm (7.5 ft. lb.) 

      NOTE: Exhaust emissions temperature sensor fitted incorrectly

      • Risk of damage to components

      → Only use prescribed lubricant when installing the sensor.

      → Carefully check the thread for damage and smear the surface with Optimol MF Paste (Part No. 000.043.207.07).

5. Remove stoppers on oil return line and turbocharger oil tank and connect line -2-  .
   1. 5.1. Fit and tighten Torx screw (M6 x 12) -1-  .

      → Tightening torque: 10 Nm (7.5 ft. lb.) 

   2. 5.2. Coat the surface of the thread and the front of the exhaust temperature sensor with Optimol MF Paste.
   3. 5.3. Fit exhaust temperature sensor -4-  on the turbocharger and screw on and tighten M12 union nut -3-  .

      → Tightening torque: 35 Nm (26 ft. lb.) +/-3 Nm (+/-2 ft. lb.) 

   4. 5.4. Fit and tighten Torx screw (M6 x 16) -5-  on oil extraction line clamp -6-  . Tighten cable holder -7-  for exhaust temperature sensor at the same time.

      → Tightening torque: 10 Nm (7.5 ft. lb.) 

      Fig 1: Identifying Oil Return Line For Cylinder 1-3

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Tighten new M8 lock nuts on the turbocharger/exhaust manifold flange and M8 x 16 Torx screw on the turbocharger holder.
   1. 6.1. Turbocharger to exhaust manifold:

      → Tightening torque: 25 Nm (19 ft. lb.) 

   2. 6.2. Screw on turbocharger holder:

      → Tightening torque: 23 Nm (17 ft. lb.) 

7. Fit intake pipe on turbocharger.
   1. 7.1. Replace O-ring and grease with Kluber Syntheso Glep. Fit intake pipe on turbocharger.
   2. 7.2. Fit and tighten two Torx screws (M6 x 20) -arrows-  .

      → Tightening torque: 10 Nm (7.5 ft. lb.) 

   3. 7.3. Connect cable plug to electronic adjuster for turbocharger -1-  until the cable plug locks with an audible click.
      Fig 2: Locating Electronic Adjuster Connector And Intake Pipe (Side 4-6)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Connect hose to control box for ambient air valve.