Disassembling And Assembling Charge-Air Cooler

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2019 Porsche 911, 2018 Porsche 911, 2017 Porsche 911, 2016 Porsche 911, and 2015 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect intake pipe -1- at the charge-air cooler.
1. 1.1. Loosen circlip -2- and remove washer -3- .
2. 1.2. Loosen clamp -4- and pull off hose -5- .
3. 1.3. Remove intake pipe -1- from the bracket.
  
  Fig 1: Identifying Intake Pipe On Charge-Air Cooler
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Loosen and remove circlips -1- and washers -2- .
1. 2.1. Press off circlips using a screwdriver.
  
  Fig 2: Identifying Circlips On Charge-Air Cooler
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Loosen bracket from the charge-air cooler.
1. 3.1. Unscrew screws -1- and remove upper part -2- of the bracket.
2. 3.2. Pull lower part -3- and braces for the bracket -4- out of the bracket.
  
  Fig 3: Removing Charge-Air Cooler Bracket
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Disassemble air guide on the charge-air cooler.
1. 4.1. Lift tab -1- and move it in direction of arrow.
2. 4.2. Remove upper part -2- and lower part -3- of the air guide.
  
  Fig 4: Removing Air Guide On Charge-Air Cooler
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Assembly is performed in reverse order. Pay particular attention to the following:
1. 5.1. Clean the surface (vanes) of the charge-air cooler.
2. 5.2. Replace damaged rubber elements.
3. 5.3. Replace damaged circlips.
4. 5.4. Tightening torque for fastening screw for brackets on upper part: 10 Nm (7.5 ftlb.) .