Installing Turbocharger On Cylinders 1 - 4

Information 

The tightening specifications for the basic engine are stored centrally.

> TECHNICAL VALUES

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> WM 2X00IN TECHNICAL VALUES (PANAMERA, PANAMERA S, PANAMERA S EXECUTIVE, PANAMERA 4, PANAMERA 4S, PANAMERA 4 S EXECUTIVE)

or

> 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information 

Before installing  the new turbocharger, remove all  the stoppers  on the turbocharger -1 and 2-  .

Ensure, in particular, that the conical rubber stopper on the connecting flange for the oil line -2-  is also removed.

In some cases, the rubber stopper, as shown in -bottom, 2-  , may be pressed slightly into the bore when the turbocharger is supplied.

As a result, it is not immediately visible from the outside - particularly when fitting the oil line.

Always remove rubber stoppers before fitting the oil line. 

• Item 1:  Plastic stoppers (not always fitted - depends on the type of packaging in which the turbocharger is supplied)
• Item 2: Rubber stopper (always  fitted) -2-  .

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Stoppers on turbocharger

Information 

Seals and sealing rings on the lines mist always be replaced.

1. Clean sealing faces between turbocharger and exhaust manifold and replace seal -2-  .

   Fit turbocharger -1-  seal -2-  and tab washers -3 and 4-  .

   Fig 1: Turbocharger Exhaust Manifold, Cylinders 1 To 4 Components Location

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   Turbocharger exhaust manifold, cylinders 1 to 4

   1	Turbocharger exhaust manifold, cylinders 1 to 4
   2	Seal; install so that marking on seal is legible
   3	Lower tab washer
   4	Upper tab washer
   5	Nut M8; turbocharger exhaust manifold to cylinder head; replace

2. Fit the turbocharger fastening screws in the prescribed sequence -1 to 12-  .
   Fig 2: Turbocharger Exhaust Manifold Fastening Screws Tightening Sequence

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   Fastening screws for turbocharger exhaust manifold

   1 to 12

   Turbocharger fastening screws

3. Fit line on turbocharger check valve. > Check valve line (cylinders 5 - 8 shown here) 

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   Check valve line (cylinders 5 - 8 shown here)

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   Check valve line (cylinders 5 - 8 shown here)

4. Fit oil lines, coolant lines and heat shield on the turbocharger.
   Fig 3: Oil Circuit For Turbocharger, Cylinders 1 To 4 Components Location

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Oil circuit for turbocharger, cylinders 1 to 4

   1	Vent line for turbocharger, cylinders 1 to 4; vent line to oil extraction line for turbocharger and holding clamp for vent line to collection pipe
   2	Turbocharger oil feed line for cylinders 1 to 4; turbocharger oil feed line on connection piece; turbocharger oil feed line on cylinder head
   not shown	Connection piece for check valve on turbocharger
   3	Holder
   4	Seal
   5	Oil extraction line
   6	Screw, M6 x 12; oil extraction line for turbocharger to oil guide housing and oil feed line for turbocharger to the holder
   7	Screw, M6 x 16

   Fig 4: Turbocharger, Cylinders 1 To 4 - Cooling Components Location

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   Turbocharger, cylinders 1 to 4 - cooling

   1	Coolant return line for turbocharger
   2	Coolant supply line for turbocharger
   3	Clip
   4	Coolant supply hose for turbocharger
   5	Turbocharger; exhaust manifold/turbocharger module

   Fit fastening screw for coolant supply line -2-  on turbocharger.

   1. 4.1.1  Secure coolant supply line in place in clip -3-  .

      Fit fastening screw for oil feed line -2-  on turbocharger.

   2. 4.2.1  Fit fastening screw -6-  for holder -3-  .

   Fit turbocharger heat shield.

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   Turbocharger heat shield (cylinders 5 - 8 shown here)

   1. 4.3.1  Insert heat shield by rotating upwards -D-  .
   2. 4.3.2  Fit the three fastening screws -A, B, C-  for the heat shield.

      Fit fastening screw for coolant return line -1-  on the turbocharger.

      Fit fastening screw for holder of turbocharger vent line -1-  . >

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      Fastening screw for holder

      Fit fastening screws for oil extraction line -6-  on the oil guide housing.

      Fit fastening screws for oil extraction line -7-  on the turbocharger.

5. Fit intake port to the turbocharger and position it according to the markings. Tighten screw-type clamp to the prescribed torque. > Tightening torque 3.5 Nm (2.5 ftlb) Nm