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Home >> Porsche >> 2019 >> 718 Boxster Base, Automatic DCT Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 7 (21 Exhaust Gas Turbocharging 2.5L -- 982 - BOXSTER/CAYMAN) >> WM, 213019 - Removing And Installing Turbocharger (VTG) >> Installing Turbocharger (VTG)

Installing Turbocharger (VTG)

WARNING: This page is about a different variant/trim than selected.

Information 

Information 

Make sure that all heat shields are fitted in the same positions again during installation.

Information 

When installing the turbocharger, make sure that it does not run dry when the engine is first started. This can damage the turbine shaft. As a precaution, fill some of the engine oil prescribed by Porsche into the turbocharger before installation.

  1. Move turbocharger and exhaust manifold -1  - into installation position.

    Information 

    When installing the exhaust manifold, always make sure that the exhaust manifold/cylinder head and exhaust manifold/turbocharger seals are positioned correctly without damaging them. Get another person to help if necessary as the three seals must be moved into installation position almost at the same time while fitting the exhaust manifold.

    1. 1.1 Position exhaust manifold -1  - with new gaskets.

      The help of another person is required. 

    2. 1.2 Position turbocharger with new gaskets.

      The help of another person is required  . Make sure that the turbocharger oil pipe is positioned correctly.

    3. 1.3 Screw-in fastening screws securing exhaust manifold to cylinder heads -2  - by a few turns in order to secure the exhaust manifold -1  -.
    G14945712Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    On vehicles with Venturi turbocharger connection: 

  2. Secure tank vent line valve -1  - at the bottom of the turbocharger -2  -.
    1. 2.1 Coat new O-rings with lubricant.
    2. 2.2 Tighten -3  - screw

      > Tightening torque 10 Nm (7.5 ftlb.) (7.4 ftlb.) 

    G14945713Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Coat new studs -2  - with hot screw paste.
  4. Screw in new studs -2  - for securing the turbocharger -3  - and tighten to > Tightening torque 12 Nm (9 ftlb.) + 4 Nm (3 ftlb.)  .

    Do not tilt the exhaust manifold and turbocharger -3  - while doing this.

    G14945714Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Fit and tighten fastening screws securing exhaust manifold to cylinder heads: > Initial tightening 15 Nm (11 ftlb.)  > Final tightening + 45°  .

    Observe the tightening sequence -1 to 12-  .

    Fig 1: Exhaust Manifold Screws Tightening Sequence
    G14945715Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Fit fastening nuts securing exhaust manifold to turbocharger and tighten to > Tightening torque 25 Nm (19 ftlb.) +/- 10 %  .
  7. Secure new V-clip -2  - securing catalytic converter -3  - to turbocharger -4  -.
    1. 7.1 Fit new gasket on flange from catalytic converter to turbocharger.
    2. 7.2 Tighten fastening screw -1  - to > Tightening torque 20 Nm (15 ftlb.)  .
    G14945716Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Secure oil pipe -1  - at the top of the turbocharger.

    Information 

    • O-rings must always be replaced. 
    • O-rings must be coated lightly with Kluber Syntheso Glep. 
    1. 8.1 Coat new O-rings with grease.
    2. 8.2 Tighten fastening screw -2  - to > Tightening torque 10 Nm (7.5 ftlb.)  .
    G14945717Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Secure turbocharger coolant line -1  - to the coolant distributor housing.

    Information 

    • O-rings must always be replaced. 
    • O-rings must be coated lightly with Kluber Syntheso Glep. 
    1. 9.1 Coat new O-rings with grease.
    2. 9.2 Insert coolant line -1  - on the coolant distributor housing.
    3. 9.3 Fit fastening screw -2  - and tighten to > Tightening torque 10 Nm (7.5 ftlb.)  .
    G14945718Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  10. Secure turbocharger coolant line -1  - to the coolant distributor housing -2  -.
    1. 10.1 Fit fastening screws -3  - and tighten to > Tightening torque 10 Nm (7.5 ftlb.)  .
    G14945719Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  11. Tighten fastening nuts -1  - securing heat shield -3  - to holder -2  - to > Tightening torque 16 Nm (12 ftlb.)  .
    G14945720Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  12. Connect vacuum hose -1  - for the wastegate vacuum modulator (VTG) -2  -.
    G14945721Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  13. Screw in exhaust temperature sensor for turbocharger -1  - and tighten to > Tightening torque 35 Nm (26 ftlb.) +/- 3 Nm (2 ftlb.)  .

    Make sure not to twist the electric line. Follow the routing of the electric line and expose it if necessary. After tightening the exhaust temperature sensor for the turbocharger -1  -, move the exposed electric line back into installation position.

    G14945722Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  14. Secure coolant line -1  - to the turbocharger -2  -.
    1. 14.1 Coat new O-rings with grease.
    2. 14.2 Position coolant line -1  - on the turbocharger -2  -.
    3. 14.3 Tighten fastening screw -3  - to > Tightening torque 10 Nm (7.5 ftlb.)  .
    G14945723Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • O-rings must always be replaced. 
    • O-rings must be coated lightly with Kluber Syntheso Glep. 
  15. Secure intake pipe -1  - to turbocharger -2  -.
    1. 15.1 Fit intake pipe -1  - on the turbocharger -2  -.
    2. 15.2 Fit fastening screws -3  - and tighten to > Tightening torque 12 Nm (9 ftlb.)  .
    G14945724Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  16. Connect electric plug connection -1  - for the VTG adjuster -2  -.
    G14945725Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  17. Secure vacuum line -1  - for brake booster to the underbody.
    1. 17.1 Check O-rings and replace them if necessary.
    2. 17.2 Connect both connection points -Arrow  -.
    G14945726Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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