Removing and Installing Oil Pump For Turbocharger
Removing And Installing Oil Pump For Turbocharger
Tools
Tools:
Removal
1. Raise the vehicle at the prescribed jacking points.
2. Disconnect battery.
3. Open engine compartment lid.
4. Remove rear spoiler.
5. Remove bumper with shield.
6. Remove lateral shields.
7. Loosen fastening nuts.
8. Loosen fastening nuts on the turbocharger. Remove the shield.
9. Detach restraining straps. Undo the two restraining straps on the rear muffler. Loosen the two -hexagon socket screws- for this purpose.
CAUTION: Falling rear muffler:
The rear muffler is loose after the restraining straps are removed. The rear muffler should be held by a second person or supported with a transmission jack.
10. Push restraining straps out of the holder. Press the restraining strap into the recesses on the engine carrier using a screwdriver and move outwards.-View from engine side-
11. Remove rear muffler. Two persons can now remove the rear muffler.
12. Undo fastening screw M 6 x 34 on the air cleaner housing.
13. Undo hose clamp between the air cleaner housing and intake manifold.
14. Tilt the complete air cleaner housing 90 degrees upward and then remove from the engine compartment.
15. Pull of the connecting hoses between the charge air coolers and the pressure pipe. Unclip the locking clips using a screwdriver and pull off the hose. Then clip the locking clips in again.
16. In order to remove the pressure pipe, loosen the hose clamps and hexagon-head bolts. Pull off the electrical plug.
17. Disconnect oxygen sensor plug on the rear closing panel.
18. Disconnect oxygen sensor plug.
19. Undo the three fastening screws of the belt pulley on the hydraulic system pump by approx. 1/2 turn.
20. Relieve drive belt. To do this turn the tensioning roller clockwise, hold and simultaneously remove the drive belt.
21. Remove pulley from the hydraulic pump.
22. Remove generator.
23. Disconnect the hydraulic lines with plug-in coupling on the expansion tank.
NOTE:
- Wear protective gloves.
- Collect emerging Pentosin.
- Protect the line against dirt and scratches with a cap.
- If hoses come into contact with Pentosin, clean them thoroughly without delay.
24. Insert tool between lines and the red unlocking ring and unlock by pulling black line to the right and simultaneously pressing the tool against the red unlocking ring
25. Unscrew two fastening screws (M8 x 25) with hexagon socket head bolts on the tank.
26. Unscrew three M8 screws and one M6 screw between the hydraulic pump and the console. Pull the expansion tank with hydraulic pump out of the bracket and suspend on the side.
27. Detach the air conditioning compressor and remove the bracket. To do this, disconnect the electrical plug connection, remove the compressor and set it down with the hoses connected.
28. Disconnect the fuel lines on the fuel cooler. Make sure to counter with a wrench when doing this.
29. Loosen hose clamps on the intake distributor and pivot the throttle body upward. Undo the fastening screws and remove the throttle body.
30. Unscrew closure cap of coolant expansion tank. Undo coolant drain plugs on right and left and drain the coolant.
31. Equip drain plugs with new sealing rings.
Tightening torque: 10 to 15 Nm (7.5 to 11.0 ftlb.).
32. Pull off the right and left coolant hoses. Lever off locking clip for this purpose.
33. Refit the locking clip on the coolant neck.
34. Remove bracket for generator. Undo hexagon-head bolts.
35. Loosen coolant neck.
36. Undo coolant hoses over the coolant pump.
NOTE:
- Tip for easier assembly:
- The coolant hoses are easier to remove when the complete bracket is removed later.
37. Loosen the stabilizer at top and swivel it downward.
NOTE: When swivelling, make sure not to damage the bellows on the lower joint:
38. Support the engine-transmission unit. Fasten special tool (retaining device) 9624/1 on the take-up points of the stabilizer mounts. The pressure disc must rest on the crankcase or crash support.
39. Separate engine carrier from the engine mounts (wrench size 18).
40. Loosen engine carrier on the bracket.
41. Secure the bracket with a shorter auxiliary screw (M10 x 55).
42. Detach the oil supply line from the bracket (right-hand side).
43. Detach the oil supply lines from the bracket (left-hand side).
44. Remove auxiliary screw again.
45. Remove complete bracket. Simultaneously pull off coolant hoses.
46. Undo oil pump fastening screws and remove the cover.
47. Check oil pump cover and contact surface of the oil pump gears in the bracket for signs of seizing or excessive wear. The entire bracket must be replaced if necessary. The bracket, oil pump gear and oil pump cover are matched.
Installation
1. Grease oil pump gears and contact surfaces with Optipitt assembly grease. Make sure that grease does not enter the receiving bores for the dowel pins.
2. Insert oil pump gears in the housing. The all-round groove of the outer oil pump gears must face the oil pump cover.
3. Fasten oil pump cover. When tightening, simultaneously check the operating smoothness of the oil pump. Tighten the screws crosswise to 10 Nm (7.5 ftlb.).
Tightening torque 10 Nm (7.5 ftlb.).
4. Prepare bracket for installation. Unscrew plug (Torx T30).
5. Fit new O-ring on the oil pump cover and new O-rings on the lower coolant connection flanges. Apply a thin coat of Vaseline on the O-rings.
6. Position bracket on the crankcase and simultaneously use a screwdriver to connect the oil pump drive shaft and the intermediate shaft. Do not use excessive force; gently press in place by hand.
7. Provisionally fasten the bracket using an auxiliary screw. The auxiliary screw can be removed again once the oil lines and coolant hoses have been fastened.
NOTE: Otherwise, the bracket is held only by the O-rings.
8. Apply Loctite 574 on the thread of the plug and fasten the plug.
Tightening torque 4 Nm (3.0 ftlb.).
9. Fit oil lines for the right-hand side. Use new O-rings.
10. Fit oil lines for the left-hand side. Use new O-rings.
11. Fit coolant lines over the coolant pump. Use water or coolant to facilitate fitting.
NOTE: If incorrectly positioned, the generator bracket would make contact and cause leaks.
12. Remove auxiliary screw.
13. Fasten engine carrier.
Tightening torque 65 Nm (48 ftlb.)
14. Fasten engine carrier on the engine mounts (wrench size 18).
Tightening torque: 85 Nm (63 ftlb.).
15. Remove special tool (retaining device) 9624/1.
16. Fasten stabilizer.
17. Install rear mufflers with new seals. The seals between the exhaust turbochargers and the rear muffler must be replaced. Move the rear muffler into installation position and push the two tensioning straps over the holder on the engine carrier.
Subsequently tighten the two hexagon socket head bolts slightly.
18. Push the heat shields over the studs of the exhaust turbocharger. Fit new hexagon nuts.
Tightening torque 30 Nm (22 ftlb.).
19. Tighten restraining straps on the rear muffler.
Tightening torque 15 Nm (11.0 ftlb.).
20. Fit heat shields, bumper and rear spoiler.
21. Install bracket for the generator. Replace the four O-rings on the two connecting flanges between the two coolant outlet necks of cylinder bank 1-3. Then screw in the four fastening screws. Important: The front right screw must be inserted with Loctite 574 (as shown in the illustration).
Tightening torque 65 Nm (48 ftlb.).
22. Check whether locking clips are properly seated.
23. Fit coolant hoses. Always replace O-rings on the coolant hoses. Wet O-rings with plenty of water.
NOTE: Never fit dry; only use water.
24. Push on coolant hose. Align the flange of the coolant hose as shown in the illustration (lug/groove). Press the coolant hose firmly against the connection neck. The coolant hose must engage audibly. Then recheck whether it is fitted properly by tilting and pulling on it.
25. Fit air-conditioning compressor. Do not forget the spacer sleeve.
26. Install throttle body.
27. Install generator.
28. Install hydraulic pump.
29. Fit drive belt.
30. Install air cleaner assembly.
31. Bleed the cooling system. Use the Porsche System Tester 2 for this purpose. Select the "Special functions" menu
32. Bleed the steering system.
33. Bring the engine to operating temperature and check it for leaks.