Ok fixed my fan noise, the LCD temp sensor wasn't stuck correctly in place.
The hardest part of the graphics upgrade was the temperature cable of the card. It belongs underneath the motherboard and is hard ot plug back in. Note: you do NOT need to remove the motherboard to install the graphics card, you can do so directly after removing the display.
As said in the beginning the initial poster claimed he had to cut a plastic piece. That is correct for late iMac 2009's only. iMacs 2010 above have the right plastic piece. Its not really difficult and easy to do:
http://i.imgur.com/Cl7Dm.jpg
Why you need to cut it? Because the three heatpipes of the 6 series card are slightly higher than the 2 of the 4 series:
http://i.imgur.com/Zmg4c.jpg
Mistakes I did:
I had to reopen the iMac often for the fan noise and once I forget the temp sensor cable and it snapped away slightly bending the connector on the motherboard. Luckily I could bend them back and connect it.
Second the vsynch cable (flat ribbon) has very fragile contacts which come of the plastic and get lose. I suggest utter carefulness with that cable. Luckily you can buy replacements for $20.
The HD temperatur sensor cable has 4 possible positions to get reconected. Luckily ifixit noticed and has a tip how to reconect: it has to be as close as possible to the SATA connector and the black cable has to be up pointing to the LCD (if its in place).
I got 2 small things with my card which I can't place, anyone knows what they are:
http://i.imgur.com/vhKbV.jpg
Heres my iMAc open with graphics card slightly removed:
http://i.imgur.com/PMhhe.jpg
Here is my iMac with the card removed:
http://i.imgur.com/HJ78c.jpg
Heres a closeup of that HD temp sensor cable and the back of the HD:
http://i.imgur.com/P0HkG.jpg
And finally the backside of the graphics card you have to remove and reapply to the new one:
http://i.imgur.com/zq2s7.jpg
The plastic piece nearly removed which I had to cut, notices: its simply glued to the surface with sticky stuff, easy to reapply:
http://i.imgur.com/dwO53.jpg
The most difficult reconnect you have to do:
http://i.imgur.com/eaFlO.jpg
See the temp sensor cable? I hope you have fine fingers 🙂
And finally, the reward for all the work:
<Image Containing S/N Edited By Host>
If anyone needs tips how to install Win7 with no DvD drive let me know, it took me 2 days to find out 😟