Installing Charge Air Cooler

Information 

The procedure for removing and installing is described for one side as an example. The procedure for the other side is almost identical.

1. Disconnect pressure hoses.
   1. 1.1 Loosen screw-type clamp -arrow -  and pull off pressure hose -1-  on the charge-air cooler -2-  .
   2. 1.2 Loosen screw-type clamp -arrow -  and pull off pressure hose -3-  on the pressure pipe -4-  .

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   Pressure hose on pressure pipe

2. Disconnect electric lines -1-  and connectors on the air guide -2-  for the charge-air cooler.
   1. 2.1 Open the holder -Arrows-  and loosen wiring harness -1-  .

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   Wiring harness on air guide for charge-air cooler

3. Loosen connector strip -1-  on the charge-air cooler.
   1. 3.1 Release connector strip -1-  (-arrow -  ) and remove it from the tab -2-  .

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   Electric lines on air guide for charge-air cooler

4. Remove charge-air cooler -1-  .
   1. 4.1 Unscrew screws -2-  and -3-  .
   2. 4.2 Move charge-air cooler outwards and remove it together with the pressure hose.

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Charge-air cooler (left)

1. Install charge-air cooler -1-  .
   1. 1.1 Position charge-air cooler with pressure hose in installation position.
   2. 1.2 Tighten screw -2-  to > Tightening torque 9 Nm (6.5 ftlb.)  .
   3. 1.3 Tighten screws -3-  to > Tightening torque 6.5 Nm (4.75 ftlb.)  .

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   Charge-air cooler (left)

2. Secure connector strip -1-  on the charge-air cooler.
   1. 2.1 Fit connector strip -1-  into the tab -2-  and lock it -arrow-  .

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   Electric lines on air guide for charge-air cooler

3. Secure electric lines -1-  and connectors on the air guide -2-  for the charge-air cooler.
   1. 3.1 Secure wiring harness -1-  at the holders -arrows-  .

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   Wiring harness on air guide for charge-air cooler

4. Secure pressure hoses.
   1. 4.1 Connect pressure hoses -1-  and -3-  and tighten screw-type clamps to -Arrows-  .

      Upper screw-type clamp:  > Tightening torque 5.5 Nm (4 ftlb.) +/- 0.5 Nm (0.3 ftlb.) 

      Lower screw-type clamp:  > Tightening torque 5.5 Nm (4 ftlb.) +/- 0.5 Nm (0.3 ftlb.) 

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Pressure hose on pressure pipe