Installing Turbocharger On Cylinders 5 - 8

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 must always be replaced.

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

   Fit turbocharger -1-  seal -2-  and tab washers -4 and 5-  .

   Fig 1: 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

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 at turbocharger check valve. > Check valve line 

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   Check valve line

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   Check valve line (cylinders 5 - 8 shown here)

4. Fit oil lines, coolant lines and heat shield at the turbocharger.
   Fig 3: 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 4: Turbocharger, Cylinders 5 To 8, Cooling Components Location

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   Turbocharger, cylinders 5 to 8, cooling

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

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

   Fit fastening screw for oil feed line -1-  at the turbocharger.

   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 supply line -2-  at the turbocharger.

   1. 4.4.1  Fit fastening screw for coolant supply line holder -3-  at the oil guide housing.

      Fit fastening screw for ventilation pipe holder on the cylinder head. >

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      Ventilation pipe holder

      Insert oil line into holder and fit fastening screw -3-  for retaining clamp -4-  .

      Fit fastening screws for oil extraction line -3-  on the oil guide housing.

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

5. Fit intake port at 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