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Removing oil-water heat exchanger

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  1. Put body-protection covers on.
  2. Disconnect battery.
  3. Remove cap on coolant expansion tank.
  4. Undo drain plug on the coolant guide housing and drain the coolants.
    Fig 1: Identifying Drain Plug On Coolant Guide Housing
    G03100348Courtesy of PORSCHE OF NORTH AMERICA, INC.
  5. Equip drain plug with a new sealing ring and fit in the coolant guide housing. Tightening torque: 10 (+) 5 Nm (7.5 (+) 3.5 ftlb.).
  6. Remove the air cleaner assembly.
    Fig 2: Identifying air cleaner assembly Screw
    G03100349Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 3: Removing MAF Sensor Connector
    G03100350Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. In vehicles with air conditioning, the following additional assembly operations must be performed: Suck Pentosin fluid out of the reservoir until the level is just below the joint.
    Fig 4: Sucking Pentosin Fluid Out Of Reservoir
    G03100351Courtesy of PORSCHE OF NORTH AMERICA, INC.

    7.1 Turn bayonet lock in the direction indicated by the arrow and pull off the reservoir. Immediately seal the lower reservoir with a suitable plug (30 mm "PHI" ).

    Fig 5: Turning Bayonet Lock
    G03100352Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Bayonett lock open 

    7.2 Disconnect battery positive at B+ disconnection point. Undo the hexagon nuts and set the box aside.

    Fig 6: Disconnecting Battery Positive At B+ Disconnection Point
    G03100353Courtesy of PORSCHE OF NORTH AMERICA, INC.

    7.3 Remove drive belt. Mark belt travel direction with a colored pen. Slacken belt, turning the tensioning pulley (wrench size 24 mm) clockwise, hold still and simultaneously take the belt off the drive pulleys.

    Fig 7: Identifying Drive (Serpentine) Belt
    G03100354Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 8: Turning Drive (Serpentine) Belt Tensioning Pulley Clockwise
    G03100355Courtesy of PORSCHE OF NORTH AMERICA, INC.

    7.4 Undo front compressor fastening screws (2 ea.). Undo rear fastening screw between the intake pipes of cylinders 4 and 5. Disconnect the electrical plug connection.

    Fig 9: Removing A/C Compressor Front Fastening Screws
    G03100356Courtesy of PORSCHE OF NORTH AMERICA, INC.

    7.5 Lift the compressor out, set it down with the hoses connected and secure it against being dropped.

  8. Undo the support between the throttle body and crankcase.
  9. Loosen outer hose clamps at intake distributor.
  10. Undo hexagon-head bolts (6 ea.) on intake distributor and take off intake distributor.
  11. Remove oil-water heat exchanger. Undo hexagon socket head bolts. Lift oil-water heat exchanger and simultaneously place a cloth or drip tray underneath it. Remove heat exchanger.