Installing Charge-Air Cooler

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Information

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

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.
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.
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.
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.
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.
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.
Further installation is performed in reverse order.