Intercooler: Service and Repair

Removing And Installing Charge Air Cooler

Tools







Technical values







Preliminary work

DANGER:
Vehicle raised incorrectly.
- Danger of fatal injury or material damage should the vehicle fall down.

- Raise the vehicle at the prescribed jacking points.

1. Remove rear wheels. Use the specified special tool socket-wrench insert P300 so as not to damage the wheel rims.
2. Remove rear apron.

Removing charge air cooler







1. Remove rapid-action coupling from bottom of suction hose and top of pressure hose by pulling the spring clamps on the charge air cooler.







2. Undo two hexagon-head bolts (M8 x 16) and one M8 hexagon nut on the charge air cooler bracket in the wheel housing.







3. Unscrew one hexagon-head bolt (M8 x 16) -2- , one M8 hexagon nut -1- on the charge air cooler bracket and one tapping screw at the rear side.







4. Screw off two speed nuts (a/f 13) on the underside of the heat protection panel.
5. Remove charge air cooler module.

Installing charge air cooler

1. Position the charge air cooler module on two threaded bolts on the body.







2. Use two hexagon-head bolts (M8 x 16) and one M8 hexagon nut to secure the charge air cooler bracket in the wheel housing.







3. Position the bracket on the rear side using one hexagon-head bolt (M8 x 16) and one M8 hexagon nut, then tighten all threaded joints. Tightening torque: 23 Nm (17 ftlb.)







4. Use two speed nuts (a/f 13) to secure the heat protection panel to the underside of the charge air cooler bracket.
5. Pre-fit the spring clamps for suction and pressure hoses on the charge air cooler.
6. Replace O-rings on suction and pressure hoses and grease them with Kluber Syntheso Glep (available from Porsche Parts Service).
7. Insert suction and pressure hoses into the rapid-action couplings on the charge air cooler. The connection must engage audibly. Pull to check that connection is secure.

Subsequent work

1. Install rear apron.
2. Mount rear wheels. Use the specified special tool socket-wrench insert P300 so as not to damage the wheel rims.