Oil Separator: Service and Repair
WM 105519 Removing and installing oil separator - Turbo
Tools
Technical values
Preliminary work
1. Raise the vehicle.
-> 4X00IN01 Lifting the vehicle 4X00IN01 Lifting the vehicle
2. Remove air cleaner housing.
-> 242519 Removing and installing air cleaner housing - Turbo - section on "Removing" Service and Repair
3. Remove tailpipe covers.
-> 263519 Removing and installing tailpipe cover - section on "Removing" Service and Repair
WARNING
Objects or loads falling down
- Risk of squashing or crushing
-> Secure components to prevent them from falling down.
Information
- It may only be supported over a large area at the oil pan.
- Localised loading is not permitted.
Information
- When lowering, the engine must not rest on the rear axle cross member.
4. Lower the engine.
4.1. Support the engine at the oil pan using the hydraulic jack HH2 WE 1033 and transmission jack plate of transmission jack V.A.G 1383 A WE 1082.
4.2. Alternative to transmission jack plate:
Mounting peg
Screw on the mounting peg 9163/2 in the middle using a wooden board (40 x 30 cm) and use it as a support.
=> Mounting peg
4.3. Loosen two special M12 nuts (internal Torx, screw insert T55) -1- on the engine mounting (hydraulic mount) at the left and right.
Engine carrier to engine mounting on cylinder bank 4-6 (view from below)
4.4. Slowly lower the engine with the hydraulic jack.
5. Remove (centre) intake-air distributor.
-> 244619 Removing and installing intake-air distributor - Turbo - section on "Removing" Service and Repair
Component information
Overview of oil separator
Removing oil separator
Information
Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:
- Torx screws: (E.) for external Torx, (T.) for internal Torx.
- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)
1. Loosen the fastening screw -1- on the cable duct -2-.
Fastening screw on cable duct
1.1. Unscrew one external Torx screw (E10) -1- on the intake-air distributor for cylinder bank 4-6.
WARNING
Hot fluid
- Danger of scalding
-> Let the fluid cool down.
-> Wear personal protective gear.
2. Disconnect coolant lines -1- for the turbocharger (cylinder 4-6) above the oil separator.
Coolant lines for turbocharger
2.1. Place a cloth under the coolant hoses.
2.2. Loosen two spring band clamps and pull off hoses.
2.3. Soak up drops of coolant with a cloth.
3. Unclip electric line for starter at the oil separator.
4. Remove oil separator.
4.1. Release and pull off the engine vent line -1- at the oil separator by pressing the locking ring.
4.2. Unscrew two external Torx screws (E10, M6 x 20) -2-.
4.3. Pull oil separator -3- off the bracket for the oil/water heat exchanger.
4.4. Close off the bores using suitable stoppers.
Oil separator
Installing oil separator
1. Remove stoppers from the bores and clean the sealing faces.
2. Replace O-rings.
2.1. Grease and fit new O-rings -1- with "Kluber Syntheso Glep" grease (Porsche Part No. 000.043.204.68).
Replacing O-rings for oil separator
3. Install oil separator.
3.1. Fit oil separator -3- into the bracket for the oil/water heat exchanger.
Oil separator
3.2. Fit and tighten two external Torx screws (E10, M6 x 20) -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
3.3. Fit and secure engine vent line -1- on the oil separator.
4. Clip in electric line for starter at the oil separator.
5. Fitting coolant lines over the oil separator
6. Fit the fastening screw -1- on the cable duct -2-.
Fastening screw on cable duct
6.1. Fit and tighten one external Torx screw (E10) -1- on the intake-air distributor (cylinder bank 4-6).
=> Tightening torque: 10 Nm (7.5 ftlb.)
Subsequent work
1. Install (centre) intake-air distributor.
-> 244619 Removing and installing intake-air distributor - Turbo - section on "Installing" Service and Repair
WARNING
Objects or loads falling down
- Risk of squashing or crushing
-> Secure components to prevent them from falling down.
2. Raise the engine.
2.1. Support the engine at the oil pan using the hydraulic jack HH2 WE 1033 and transmission jack plate of transmission jack V.A.G 1383 A WE 1082.
2.2. Alternative to transmission jack plate:
Mounting peg
Screw on the mounting peg 9163/2 in the middle using a wooden board (40 x 30 cm) and use it as a support.
=> Mounting peg
2.3. Slowly lift the engine with the hydraulic jack.
Engine carrier to engine mounting on cylinder bank 4-6 (view from below)
2.4. Tighten two special M12 nuts (internal Torx, screw insert T55) -1- on the engine mounting (hydraulic mount) at the left and right.
=> Tightening torque: 85 Nm (63 ftlb.)
3. Install tailpipe covers.
-> 263519 Removing and installing tailpipe cover - section on "Installing" Service and Repair
4. Install air cleaner housing.
-> 242519 Removing and installing air cleaner housing - Turbo - section on "Installing" Service and Repair