Removing Charge Air Cooler

Fig 1: Identifying Air Guide For V8 Turbo

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

→ Switch off ignition and remove ignition key or remote control (hand-held transmitter).

→ A voltage supply (e.g. battery charger) must not be connected to the external power supply/jump-lead starting terminals.

→ Disconnect the battery and insulate the ground strap so that all contact with a ground carrier is avoided.

→ Wait 1 minute after disconnecting the battery.

→ Only detach connector on the triggering unit after the waiting time has elapsed.

→ Make sure that no foreign objects are located in front of the airbag unit during installation.

→ Replace damaged parts during removal.

→ Always position airbag units so that the blow-out opening is facing upwards, e.g. crest on driver's airbag.

→ Do not position anything on the airbag units.

→ If removed for an extended period, the airbag units must be stored in a safe place.

→ Airbag units must not come into contact with grease, oil, detergents, liquids, or similar substances.

→ Do not expose airbag units to temperatures above 90°.

→ Do not remove the short-circuit spring on the plug-in contacts.

→ Ignition and preparations may only be carried out by skilled staff, supervised by a second responsible person.

→ Before disposal, the airbag unit must be rendered harmless by electrical ignition performed in accordance with all precautionary measures, thereby preventing it from being used incorrectly.

Information 

When disconnecting the airbag sensor, make sure that both the cable going from the sheet metal clip to the air guide and the cable plug for the airbag sensor are removed.

1. Release airbag sensor cable from sheet metal clip. Leave cable plug on the airbag sensor.
   Fig 2: Removing Airbag Sensor Cable

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Pull air guide in front of the charge air cooler off sideways.
   Fig 3: Pulling Air Guide

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Slide air guide behind the charge air cooler off sideways.
   Fig 4: Identifying Air Guide Wheel Housing

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Air guide
   2. Charge air cooler
4. Disconnect the lower right pressure pipe. To do this, lever off the wire clip using a screwdriver -1-  and pull off the pipe. Put wire clip back into installation position immediately. Lower pressure pipe Release wastegate line and pull it off -A-  .
   Fig 5: Identifying Lower Pressure Pipe

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   Fig 6: Identifying Pressure Pipe With Pressure Hose At Right

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   Fig 7: Identifying Ambient Air Valve At Right (Above Pressure Pipe)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Intake manifold
   2. Hose clamp
   3. Wastegate hose
      Fig 8: Identifying Bottom Right Pressure Pipe To Charge Air Cooler Connections

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Pressure pipe
   2. Connecting coupling
   3. Wastegate hose
   4. Charge air cooler
5. Disconnect the lower left pressure pipe -4-  . To do this, lever off the wire clip using a screwdriver and pull off the pipe. Put wire clip back into installation position immediately. Release wastegate line and pull it off -1-  .
   Fig 9: Identifying Left Pressure Pipe

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Wastegate hose
   2. Intake manifold
   3. Turbocharger
   4. Pressure pipe
   5. Charge air cooler
6. Unscrew the two hexagon socket head bolts (M6 x 20) on the pressure pipe and pull off the pressure pipe.
   Fig 10: Locating Pressure Pipe Mount (Left)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   Fig 11: Identifying Upper Boost Pressure Pipe Connection (Right)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Wastegate control line
   2. Pressure pipe
   3. Screw securing pressure pipe to charge air cooler
   4. Wastegate control line
   5. Installation marking
      Fig 12: Identifying Upper Boost Pressure Pipe Connection (Right)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Pressure pipe
   2. Wastegate control line
   3. Installation view
   4. Screw securing pressure pipe to charge air cooler
   5. Ambient air valve
   6. Intake manifold
7. Pull off air guide to air cleaner housing.
   Fig 13: Pulling Air Guide

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Unscrew the three fastening screws on the charge air cooler, press the charge air cooler carefully towards the tires and remove sideways. Sleeves -2-  generally fall down.
   Fig 14: Locating Charge Air Cooler Fastening Screws

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   Fig 15: Locating Charge Air Cooler On Bracket

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. Screws
   2. Sleeves
   3. Charge air cooler