Techart 070.300.630.009 User manual

ASSEMBLY INSTRUCTIONS
TECHART Power-Kit TA 070/T2
for Panamera Turbo
Part-No.: 070.300.630.009 Panamera Turbo

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Contents
IImportant safety information.....................................................................................................................3
II Preparation..................................................................................................................................................4
III Installation...................................................................................................................................................7
1Preparing the vehicle .........................................................................................................................7
2Removing the original parts ...............................................................................................................8
2.1 Removing the original DME control unit................................................................................8
2.2 Removing the original engine ...............................................................................................9
2.3 Removing the original exhaust turbochargers.................................................................... 10
3Installing the TECHART parts......................................................................................................... 11
3.1 TECHART components, bank 1 (cylinders 1 - 4)............................................................... 11
3.2 TECHART components, bank 2 (cylinders 5 - 8)............................................................... 15
3.3 Installing the TECHART sport air filter............................................................................... 20
3.4 Installing the original engine............................................................................................... 22
3.5 Installing the TECHART engine styling package ............................................................... 23
4Performing final work on the vehicle............................................................................................... 24
4.1 Finishing touches ...............................................................................................................24
4.2 TECHART recommendations............................................................................................. 25
4.3 Final inspection .................................................................................................................. 26
5Tightening torques .......................................................................................................................... 27

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I Important safety information
All of the necessary work must be performed by qualified persons with an appropriate
level of expertise.
Vehicle lifts with an insufficient lifting capacity can collapse under the weight
of the vehicle and crush any persons standing underneath.
Compare the weight of the vehicle with the lifting capacity of your vehicle lift.
The weight of the vehicle must not exceed the lifting capacity of your vehicle
lift. The weight of the vehicle can be found in the vehicle operating manual.
Risk of injury from electric current.
Switch off the ignition and disconnect the battery when working on the vehicle
electrical/electronics systems.
Risk of injury from hands and arms being crushed, cut or lacerated when
working with sharp-edged and bulky objects.
Wear protective clothing and protective gloves. Keep limbs out of narrow and
inaccessible areas of the vehicle and/or avoid dangerous situations by using
special tools and suitable aids.
Risk of injury to back, muscles, joints, tendons and ligaments from lifting and
carrying heavy and/or bulky objects.
Lift and transport heavy and/or bulky objects with the help of other people
and/or with suitable aids.
Before starting the assembly procedure, carefully read the assembly instructions in full
and pay attention to the safety information and sequence of the individual operation steps.

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II Preparation
Number of people required
At least two people are required to install this product.
Help and support
In case of technical queries, contact us immediately: [email protected]
Check TECHART parts kit for completeness
Quantity Part number Part designation
1 070300800102 Center cover
1 00091089010031 Klebt + Dichtet (adhesive sealant) black, 70ml tube
1 070300800209 Sport air filter
1 070300630200 Assembly kit turbocharger cylinder 1-4 T2
Consisting of:
1 94811118170 Gasket
12 99908464202 Hexagon nut
1 97011111571 Gasket
6 N90894602 Hexagon nut M8
4 90012300530 Washer
1 99970776340 O-Ring
2 90012300530 Washer
1 99970756840 O-Ring
1 94810712350 Gasket

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1 070300630201 Assembly-Kit turbocharger cylinder 5-8 T2
Consisting of:
1 94811118170 Gasket
12 99908464202 Hexagon nut
1 97011111570 Gasket
6 N90894602 Hexagon nut M8
4 90012300530 Washer
1 99970776340 O-Ring
1 99970750340 Washer
2 90012300530 Washer
1 99970756840 O-Ring
1 94810712350 Gasket
1 070300630300 Turbocharger R T2 cylinder 1-4
1 070300630301 Turbocharger R T2 cylinder 5-8
1 070300265500 Crankcase ventilation hose T2
1 070300600350 Assembly-Kit engine
Consisting of:
6 N90941703 Cylinder screw M10x45
6 90037830901 Combination screw
1 97032180500 Locking screw with gasket
2 N90666001 O-Ring 11.5x3
1 N90842402 Combination screw M6x22
4 99907287101 Hexagon screw M12x1,5x75
2 99907287301 Hexagon screw M12x1.5x130
2 99908444909 Hexagon screw M12x1.5
2 99907415001 Twelve point screw M12x1.5x95
2 99908444501 Locknut M12x1.5
2 99908444909 Hexagon nut M12x1.5
1 WHT004955 Torx screw
4 99907346101 Cylinder screw M14x1.5x135
1 99970743941 O-Ring 23,80x2,4
1 99970755741 O-Ring 11,00x2,5
2 N10414402 Combination screw M8x28
1 000300101OKT Octane 100 decal

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Please use the table to check whether all of the required parts are present.
Please contact us immediately if any parts should be missing: [email protected]
Once parts have been removed from their original packaging, ensure that they are
properly handled and stored.

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III Installation
1 Preparing the vehicle
1 Raise the vehicle at the factory-fitted jacking points.

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2 Removing the original parts
2.1 Removing the original DME control unit
i
Before removing the control unit, read out the fault codes and generate a fault
log (if any DME-relevant faults are present, these must be rectified before the
performance kit is installed).
Always switch off the ignition and disconnect the battery when working on the
vehicle electrical system. Only reconnect the battery when all connectors and
control units are plugged in correctly.
Fig. 01
Fig. 02
1 Switch off the ignition and disconnect the battery.
2 Loosen and lift off the plastic cover of the front right water tank.
3 Unscrew the bolts from the bracket of the original control unit (DME) and remove
the bracket.
4 Loosen both compact connectors and pull off with care.
5 Take out the original control unit (DME).
i
Label the original DME control unit with the VIN and send to the following
address:
TECHART Automobildesign GmbH
> Wareneingang <
Roentgenstrasse 47
71229 Leonberg, Germany

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2.2 Removing the original engine
Please note the manufacturer’s safety instructions and all local laws and
regulations governing health and safety and accident prevention.
1 Remove the engine/transmission unit with integral carrier and front axle according
to the manufacturer’s instructions.

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2.3 Removing the original exhaust turbochargers
Warning! Exhaust system may be hot!
1 Unhinge the lambda probe cable from the clips.
i
Important: Ensure absolute cleanliness when removing the
turbocharger!
Engine oil and coolant may escape, use a suitable receptacle.
2 Dismantle the catalytic converter unit.
3 Dismantle the heat protection exhaust turbocharger.
4 Dismantle all cooling water-, oil- and ventilation pipes.
5 Dismantle the hose pipe at the pressure sensor for the bypass-flaps, and
dismantle the control pressure line at the exhaust turbocharger bank 1 (cylinder 1
to 4).
6 Loosen oil inlet and oil outlet pipes.
7 Loosen control line of the wastgate-sensor and control pressure line at the
compressor casing.
8 Loosen the original exhaust turbocharger/-manifold for that loosen 12 nuts at the
manifold flange (cylinder head).
9 Remove all screws and nuts and remove the original exhaust turbocharger/-
manifold.
10 Clean the sealing surfaces!
i
The original exhaust turbochargers are no longer required.

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3 Installing the TECHART parts
3.1 TECHART components, bank 1 (cylinders 1 - 4)
i
Important: Ensure absolute
cleanliness when installing the
turbocharger!
All washers of the hollow bolts have
to be exchanged for new ones (see
photo).
Fig. 03
1 Position the internal coolant flow
on the TECHART turbocharger,
align forward towards the coolant
hose and tighten.
2 Position the TECHART
turbocharger.
New gasket (948.111.181.70) and
nuts M8. Use the original safety
plates.
Mount all nuts with some aluminum
paste to the thread.
3 Just attach all nuts, do not tighten!
4 Attach the oil return pipe (1) with
the new gasket 948.107.123.50 (2)
and tighten.
Fig. 04
2
1

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5 Install the external coolant return
line, oil supply line and ventilation
line (see arrows).
i
Pour a little engine oil into the oil
supply line connection, to ensure
immediate lubrication of the
turbocharger.
Fig. 05
6 Install the original hose line to the
control sensor for the bypass flap.
+Fig. 06
7 Connect the original control
pressure line (see arrow) to the
TECHART turbocharger.
Fig. 07

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8 Install original catalytic converter
unit.
i
Use new gasket and new nuts M8.
Coat the thread of all nuts and bolts
with a little aluminum paste.
Only screw in nuts and bolts, do not
tighten!
Fig. 08
9 Fasten the bracket of the catalytic
converter unit to the transmission
bell housing.
Fig. 09
10 Uniformly tighten all nuts and bolts
on the TECHART exhaust
turbocharger/-manifold and
catalytic converter unit.
i
Note the specified tightening
torques and sequence (1-12),
exemplified photo!
Fig. 10

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11 Install the original heat protection
to the TECHART turbocharger and
to the cylinder head.
Fig. 11
12 Hook the cable of the lambda
sensor into the designed holding
clips.
i
Ensure that lines are correctly
routed!
Make sure that lambda sensor
cables are not under tension!
Fig. 12

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3.2 TECHART components, bank 2 (cylinders 5 - 8)
i
Important: Ensure absolute
cleanliness when installing the
turbocharger!
All washers of the hollow bolts have
to be exchanged for new ones (see
photo).
Fig. 13
1 Position the internal coolant flow
on the TECHART turbocharger,
align forward towards the coolant
hose and tighten.
2 Position the TECHART
turbocharger.
New gasket (948.111.181.70) and
nuts M8. Use the original safety
plates.
Mount all nuts with some aluminum
paste to the thread.
3 Just attach all nuts, do not tighten!
4 Attach the oil return pipe (1) with
the new gasket 948.107.123.50 (2)
and tighten.
Fig. 14
2
1

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5 Install the external coolant return
line, oil supply line and ventilation
line (see arrows).
Fig. 15
i
Pour a little engine oil into the oil supply line connection, to ensure immediate
lubrication of the turbocharger.
6 Install the original hose line to the
control sensor for the bypass flap.
Fig. 16
i
Align the original fastening eyelet (3) in such a way that the hose (4) can be put
through it from above.
3
4
3
4

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7 Connect the original control
pressure line to the TECHART
turbocharger.
8 Install original catalytic converter
unit.
i
Use new gasket and new nuts M8.
Coat the thread of all nuts and bolts
with a little aluminum paste.
Only screw in nuts and bolts, do not
tighten!
Fig. 17
Fig. 18

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9 Fasten the bracket of the catalytic converter unit to the transmission
bell housing.
Fig. 19
10 Uniformly tighten all nuts and bolts
on the TECHART exhaust
turbocharger/-manifold and
catalytic converter unit.
i
Note the specified tightening
torques and sequence (1-12),
exemplified photo!
Fig. 20
11 Install the original heat protection to
the TECHART turbocharger and to
the cylinder head.
Fig. 21

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12 Hook the cable of the lambda
sensor into the designed holding
clips.
i
Ensure that lines are correctly
routed!
Make sure that lambda sensor
cables are not under tension!
Fig. 22

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3.3 Installing the TECHART sport air filter
i
Remove the front apron first, since the air filter housing lies below it.
Fig. 23
1 Open engine hood.
2 Dismantle main headlights.
3 Remove the PU-cover around the hood lock.
4 Unscrew the upper 4 fixing screws (see arrows).
5 Remove the retaining brackets (1) right and left between the headlight and flap
towards the flap.
Fig. 24