1

Collect escaping fluids.
Loosen plug-in coupling for oil
supply line/oil tank and collect oil
using the oil drip pan.
1
2
3
4

3.1.2

3.1.3

– Oil supply line for
turbocharger (cyl. 1–3)
– Oil tank for turbocharger
(cyl. 1–3)
– Bypass control box on
turbocharger (cyl. 1–3)
– Tank ventilation line flange
(cyl. 1–3)

Figure 21
Remove Torx screw (M6 x 12)
on the turbocharger oil tank (cyl. 1–3/cyl. 4–6) and remove oil tank from the
respective turbocharger.
ONLY for turbocharger (cyl. 1–3):
1

2

•

•
•

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– Mounting for bypass
control box on
turbocharger (cyl. 1–3)
– M8 hexagon nut on
turbocharger/exhaust
manifold flange (cyl. 1–3)
Remove Torx screw (M6 x 12)
on tank ventilation line flange
and carefully loosen the flange
( Figure 21 -4-).
Remove bypass control box
with linkage.
Removing turbocharger vent line

Tequipment

Figure 22

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3.1.4

Remove turbocharger bracket (cyl.
1–3/cyl. 4–6)  Figure 23 -1-.
1
2

3.1.5

– Bracket
– Turbocharger (cyl. 4–6)

Remove turbocharger (cyl. 1–3/cyl.
4–6) from exhaust manifold (cyl.
1–3/cyl. 4–6) and carefully guide it
out past the lines.

Information
The seals must always be replaced following
removal.

Figure 23

Information
•

Fit new O-rings on engine oil lines.

•

Grease O-rings with a light coating of Klüber Syntheso Glep.

•

Remove stoppers before fitting the engine oil lines.
Information

3.2

•

Fit new O-rings on coolant lines.

•

Coat O-rings lightly with Klüber Plus Gel.

•

Remove stoppers before fitting the coolant lines and hoses.

Replace all seals and O-rings on the lines for
the turbocharger (cyl. 1–3  Figure 24/cyl.
4–6).
1
2
3
4
5

3.3

Figure 24

Install new turbocharger (cyl. 1–3/cyl. 4–6)
3.3.1

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– O-ring, 10 x 3 – oil return line (cyl.
1–3)
– O-ring, 10 x 3 – oil supply line (cyl.
1–3)
– O-ring, 10 x 3 – coolant
return/supply line (cyl. 1–3)
– O-ring, 10 x 3 – oil circuit vent line
(cyl. 1–3)
– O-ring, 13 x 3 – tank ventilation line
ONLY for cyl. 1–3

ONLY for turbocharger (cyl. 1–3):
Remove bypass control box on the new turbocharger (cyl. 1–3).

Tequipment

2017© Porsche Cars North America, Inc.

Installation and Conversion Instructions
3.3.2

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Position turbocharger (cyl. 1–3/cyl. 4–6) together with the turbocharger bracket
and new seal on the respective exhaust manifold.
•
•

Loosely fit M8 hexagon nuts (3 on each side, exhaust manifold).
Loosely fit M8 x 35 screw (1 on each side, bracket).

3.3.3

Guide all lines into the turbocharger connections (cyl. 1–3/cyl. 4–6).

3.3.4

Replace O-ring, 15 x 2.5 (1 x) on the
turbocharger oil tank (cyl. 1–3/cyl.
4–6) with a new O-ring ( Figure
25).
1
2
3

– O-ring, 15 x 2,5
– Oil tank for turbocharger
(cyl. 1–3)
– Oil tank for turbocharger
(cyl. 4–6)

Fit turbocharger oil tank (cyl.
1–3/cyl. 4–6) on the respective
turbocharger using two Torx screws
(M6 x 20).

Figure 25

Tightening torque 10 Nm (7.5 ftlb.)
3.3.5

ONLY for turbocharger (cyl. 1–3):
Install bypass control box on the
new turbocharger using two M6
hexagon nuts.
1
2

– Bypass control box
– Hexagon nut, M6

Hexagon nut, M6: Tightening
torque 7 Nm (5 ftlb.) +1 Nm
(+0.5 ftlb.)
3.3.6

Tighten Torx screw (M6 x 12)
on all lines/connections for the
turbocharger (cyl. 1–3/cyl. 4–6).

Figure 26

Tightening torque 10 Nm (7.5 ftlb.)
3.3.7

Tighten one Torx screw (M8 x 35) on the turbocharger bracket (cyl. 1–3/cyl. 4–6).
Tightening torque 23 Nm (17 ftlb.)

3.3.8

Tighten three M8 hexagon nuts on the turbocharger (cyl. 1–3/cyl. 4–6) for the
exhaust manifold flange.
Tightening torque 25 Nm (19 ftlb.)

2017© Porsche Cars North America, Inc.

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3.3.9
3.4

Installation and Conversion Instructions

8/17

Connect vacuum line to bypass control box on turbocharger (cyl. 1–3/cyl. 4–6).

Fit intake pipe on the turbocharger (cyl. 1–3/cyl. 4–6)
3.4.1

Replace one O-ring (45 x 3) on the
intake pipe.
1
2

– O-ring, 45 x 3
– Intake pipe (cyl. 1–3)

Figure 27
3.4.2

Install intake pipe on turbocharger
(cyl. 1–3) using new clips (hose
clamp 50–70/clip).
1
2
3
4
5
6

3.4.3

– Intake pipe on
turbocharger (cyl. 1–3)
– Hose clamp, 50–70
– Clip, ∅ 75
– Charge air hose on
turbocharger (cyl. 1–3)
– Hose clamp, 50 - 70 x 12
– Hose clamp, 40 - 60 x 12

Figure 28
Connect plug connection at the
point where the turbocharger intake pipe (cyl. 4–6) branches to the positive
crankcase ventilation line.
Install intake pipe on turbocharger (cyl. 4–6) using a new clip (hose clamp 50–70
and clip).

3.4.4

Tighten clips on intake pipe.
Hose clamp, 50–70/charge-air cooler insulation: Tightening torque 3 Nm
(2 ftlb.)
Clip/turbocharger intake connection: Tightening torque 5 Nm (3.5 ftlb.)

3.5

Install charge air hose on turbocharger (cyl. 1–3/cyl. 4–6) using two new hose clamps (40 60 x 12).
Clip/turbocharger intake connection: Tightening torque 5.5 Nm (4 ftlb.)

3.6

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Install drain plug (M14 x 1.5) on thermostat housing with a new sealing ring (14 x 18).

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Tightening torque 25 Nm (19 ftlb.)
4

Install (sport) exhaust system
4.1

ONLY for vehicles WITH sport exhaust system (I-no. 176), i.e. parts scope
991.044.100.10:
Install old sport exhaust system with new seal between turbocharger and catalytic converter
(2 x) and new clamp on main silencer (2 x) (  Workshop Manual '260119 Removing and
installing exhaust system').

4.2

ONLY for vehicles WITHOUT sport exhaust system (I-no. 176), i.e. parts scope
991.044.100.11:
Install new sport exhaust system (1 x) with new seal between turbocharger and catalytic
converter (2 x) and new clamp on main silencer (2 x) (  Installation and Conversion
Instructions '260100 Sports exhaust system (I-no. 176)' and  Workshop Manual '260119
Removing and installing exhaust system').

4.3

Install heat shield on turbocharger (cyl.
1–3  Figure 29/cyl. 4–6) using four
countersunk screws (M6 x 10) (  Workshop
Manual '261219 Removing and installing heat
shield').
1
2

– Heat shield on turbocharger (cyl.
1–3)
– Countersunk screw, M6 x 10

Tightening torque 10 Nm (7.5 ftlb.)
5

Concluding work

Figure 29

5.1

Fit bumper and heat protection panels (  Workshop Manual '635019 Removing and
installing rear bumper').

5.2

Fit rear apron (  Workshop Manual '635519
Removing and installing rear apron').

5.3

Fit rear wheels (  Workshop Manual
'440519 Removing and installing wheel') and lower the vehicle.

5.4

ONLY for Cabriolet: Move convertible-top
compartment lid to normal position.

5.5

ONLY for vehicles WITHOUT Porsche
Ceramic Composite Brake (PCCB = 450) and/or rear axle steering (470):
5.5.1

Move electric parking brake (EPB)
out of "assembly position" into "normal position" using 9900 - PIWIS Tester 3.

2017© Porsche Cars North America, Inc.

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5.5.2

Tighten new hexagon nut (M22 x
1.5) on the rear-axle drive shaft (at the left/right) when the vehicle is standing on
the ground.
Tightening torque 460 Nm
(340 ftlb.)

5.5.3
5.6

Fit hub cap on wheel (at the
left/right) on the rear axle.

Remove old engine compartment cover and
replace it with the new "Exclusive Powerkit"
engine compartment cover (  Workshop
Manual '198119 Removing and installing
engine-compartment blower').
1
2

– "Exclusive Powerkit" engine
compartment cover ASSY
– Carbon inserts

Pull protective film off the carbon inserts
( Figure 30).
Figure 30
NOTICE
Voltage drop
•

Risk of irreparable damage to control unit

•

Risk of damage to control unit

•

Fault entries in the control unit

•

Coding in the control unit is aborted

•

Malfunctions in control unit, even during programming



Switch off the ignition and remove the ignition key before disconnecting the control unit.



Ensure that the power supply is not interrupted during programming.



Connect a battery charger with a current rating of at least Nominal value 70 A to the vehicle battery.
6

Code/program Power Kit ( I-no. X51) and sport exhaust system (I-no. 176), if not already installed
Read and follow the basic instructions and procedure for control unit programming using the PIWIS
Tester (  Workshop Manual '9X00IN Basic instructions and procedure for control unit programming
using the PIWIS Tester').
6.1

Preparatory work
6.1.1

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Connect battery charger (  Workshop Manual '2X00IN Battery trickle charging').

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Installation and Conversion Instructions

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1

NOTICE
Control unit programming will be aborted if the Internet connection is unstable.
•

An unstable Internet connection can interrupt communication between PIWIS Tester
III and the vehicle communication module (VCI). As a result, control unit programming
may be aborted.



During control unit programming, always connect PIWIS Tester III to the vehicle
communication module (VCI) via the USB cable.
6.1.2

9900 - PIWIS Tester 3 must be connected to the vehicle and switched on.

6.1.3

Check PIWIS Tester software version (at least 35.600.010) in the footer on the
Start screen.

6.1.4

Switch on ignition AND hazard warning lights on the vehicle.
Information
The 9900 - PIWIS Tester III instructions take precedence since the description
may be different with later Tester releases.
The procedure described here has been structured in general terms; different text
or additions may appear on the 9900 - PIWIS Tester III.

6.2

6.1.5

Select the "Diagnostics" menu item on the PIWIS Tester.

6.1.6

If 9900 - PIWIS Tester 3 is connected correctly, a connection to the vehicle will be
established: "Model line 991" is detected.

Read out the current part number of the DME control unit
6.2.1

Select "DME (digital engine electronics)" in the control unit overview and switch to
"Extended identifications".

6.2.2

All data relating to the DME control unit is displayed.
Example: DME Carrera S B6T 3.0 l RoW with “Porsche part number of DME” =
9P1.906.023.BL

6.2.3
6.3

Take a note of the Porsche part number before starting programming. Press
•