Removing Turbocharger On Cylinders 5 - 8

Information 

• When removing the turbocharger take note of the connection points for the lines. 
• The installation position of the lines that are screwed to the turbocharger must be marked before disconnecting them. 
• During reinstallation, the lines must be stress-free and must not be bent. 

1. Loosen intake port on the turbocharger and remove intake port.
2. Remove oil lines, coolant lines and heat shield on the turbocharger.
   Fig 1: Oil Circuit For Turbocharger, Cylinders 5 To 8 Components Location

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   Oil circuit for turbocharger, cylinders 5 to 8

   1	Oil feed line for turbocharger, cylinders 5 to 8; oil feed line for turbocharger to connection piece; oil feed line for turbocharger to cylinder head
   2	Vent line for turbocharger, cylinders 5 to 8; vent line to oil extraction line for turbocharger
   3	M6 screw; oil extraction line for turbocharger to oil guide housing and holding clamp
   4	Holding clamp
   not shown	Connection piece for check valve to turbocharger
   5	Oil extraction line
   6	Screw, M6 x 16
   7	Seal

   Fig 2: Turbocharger, Cylinders 5 To 8, Cooling Components Location

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Turbocharger, cylinders 5 to 8, cooling

   1	Coolant return line for turbocharger
   2	Coolant supply line for turbocharger
   3	Bracket for coolant supply line to oil guide housing

   1. 2.1  Remove fastening screws for oil extraction line -6-  on turbocharger.
   2. 2.2  Remove fastening screws for oil extraction line -3-  on oil guide housing.
   3. 2.3  Remove fastening screw -3-  for retaining clamp -4-  and take oil line out of holder.
   4. 2.4  Remove fastening screw for ventilation pipe holder on the cylinder head. >

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      Ventilation pipe holder

   5. 2.5  Remove fastening screw for coolant supply line -2-  on the turbocharger.
      1. 2.5.1  Remove fastening screw for coolant supply line holder -3-  to the oil guide housing.
   6. 2.6  Remove turbocharger heat shield.

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      Turbocharger heat shield (cylinders 5 - 8 shown here)

      1. 2.6.1  Remove the three fastening screws -A, B, C-  for the heat shield.
      2. 2.6.2  Remove heat shield by rotating downwards -D-  .
   7. 2.7  Remove fastening screw for oil feed line -1-  on the turbocharger.
   8. 2.8  Remove fastening screw for coolant return line -1-  on the turbocharger.
3. Pull off line on turbocharger check valve. >

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   Vacuum unit line (shown here on cylinders 5 - 8)

4. Remove the turbocharger fastening screws -1 to 12-  .
   Fig 3: Turbocharger Exhaust Manifold Fastening Screws Loosening Sequence

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   Fastening screws for turbocharger exhaust manifold

   1 to 12

   Turbocharger fastening screws

5. Remove turbocharger -1-  seal -2-  and tab washers -4 and 5-  .
   Fig 4: Turbocharger Exhaust Manifold, Cylinders 5 To 8 Components Location

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   Turbocharger exhaust manifold, cylinders 5 to 8

   1	Turbocharger exhaust manifold, cylinders 5 to 8
   2	Seal; install so that marking on seal is legible
   3	Nut M8; turbocharger exhaust manifold to cylinder head; replace
   4	Upper tab washer
   5	Lower tab washer