Removing Upper Coolant Pipe

→ Ventilate the work area well.

→ Never ingest or inhale.

→ Read specific information on the Hazard Sheet.

→ Do not smoke, eat or drink in the work area.

1. Drain coolant. → 193817 DRAINING AND FILLING COOLANT (INCLUDES BLEEDING) 
2. Remove compressor. → 211419 REMOVING AND INSTALLING COMPRESSOR
3. Unclip line -1-  . Screw off nuts -arrows-  and remove protective plate -2-  .
   Fig 1: Locating High-Pressure Pump Protective Plate

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Remove lower part of intake manifold at the right. → 244719 REMOVING AND INSTALLING INTAKE MANIFOLD
5. Move hose -arrow-  for secondary air forward out of the holder and disconnect it by pressing the release buttons. Release hose for secondary air and vacuum hoses and press them aside.
   Fig 2: Locating Secondary Air Hose

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   NOTE: Dirt on injection system components

   • Material damage
   • Rough-running engine
   • Bad exhaust emissions

   → Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.

   → Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.

   → Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.

   → Only install clean parts. Do not take spare parts out of the packaging until just before installation.

   → Never use compressed air when the system is open. Do not move the vehicle.

   WARNING: Highly inflammable or explosive materials

   • Danger of fire or explosion

   → Avoid contact with hot parts or sources of ignition.

   → Use suction to remove ignitable vapors.

   → Attach warning sign in a clearly visible position.

   Information 

   • Do not bend high-pressure lines. Always remove the high-pressure distributor pipe and other fuel-supply components in the high-pressure area completely. Check that the connection points are not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks following fitting  .

   Information 

   • Absorb any escaping fuel using a suitable binding material or a cloth  .
   • Cloths which have absorbed fuel must be disposed of according to the applicable national laws  .
   • The fuel system must be depressurized before starting work on it  .
   • Only work on the fuel system in well-ventilated rooms  .
   • Any seals which have been removed must always be replaced  .
   • Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors  .
6. Unscrew threaded connection -1-  and union nut -3-  . Unscrew screws -arrows-  on the retaining clips and remove high-pressure line.
   Fig 3: Locating High-Pressure Line Plug Connection

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   WARNING: Hot fluid

   • Danger of scalding

   → Let the fluid cool down.

   → Wear personal protective gear.

7. Remove coolant hose from the coolant pipe. Unscrew screw and pull coolant pipe to the rear and out of the cylinder block.
   Fig 4: Removing Coolant Hose From Coolant Pipe

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.