Installing Charge-Air Cooler

Information 

For tightening torques, tightening sequence and assembly overview, see → 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS

1. Charge-Air Cooler Seals: 
   1. 1.1. Check the seal -5-  on the charge-air cooler -4-  .
   2. 1.2. The seal must not be cracked or damaged.
   3. 1.3. Push the seal -1-  onto the charge-air cooler.
   4. 1.4. Insert O-ring -2-  into the opening on the compressor housing -3-  .
      Fig 1: Identifying Charge-Air Cooler Seals

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Charge-Air Cooler Sealing Surfaces: 
   1. 2.1. Coat the sealing surface -arrow A-  and seal -arrow B-  on the charge-air cooler -1-  with engine oil.
   2. 2.2. Also coat the inner sealing surface in the compressor housing with engine oil.
      Fig 2: Locating Charge-Air Cooler Sealing Surfaces

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Information 

      To make it easier to slide in and press back the charge-air cooler, position the compressor housing vertically in the engine and gearbox support VAS 6095.

3. When fitting the charge-air cooler, make sure that the seals are aligned with the cut-outs in the compressor housing -arrows-  .
   Fig 3: Locating Charge-Air Seals And Cut-Outs

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Slide the charge-air cooler as far as it will go by hand  into the compressor housing -arrow A-  . To do this, slide the front of the charge-air cooler into the bore -arrow B-  in the compressor housing.
   Fig 4: Sliding Charge-Air Cooler

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Guide the charge-air cooler through the openings -arrows-  on the compressor housing by hand if necessary when inserting it.

   As soon as the screw length allows it, screw in two screws loosely by hand to guide the charge-air cooler further.

   Fig 5: Identifying Compressor Housing Openings

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Tighten screws -1, 2-  for the charge-air cooler at the left and -3, 4-  for the charge-air cooler at the right in diagonally opposite sequence and in small steps.
   Fig 6: Identifying Charge-Air Cooler Screws

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Further installation is performed in reverse order.