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Home >> Porsche >> 2019 >> 718 Boxster Base, Automatic DCT Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 7 (21 Exhaust Gas Turbocharging 2.5L -- 982 - BOXSTER/CAYMAN) >> WM, 214319 - Removing And Installing Charge Air Cooler >> Installing Charge Air Cooler

Installing Charge Air Cooler

WARNING: This page is about a different variant/trim than selected.
WARNING: Caustic fluids 
  • Danger of chemical burns 
    • → Wear personal protective gear.
    • → Ensure that there is good ventilation.
    • → Avoid contact with caustic fluid.
    • → If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

Component overview of charge-air cooling system: 

Fig 1: Charge-Air Cooling System Components Location
G14945752Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Charge air cooler
  2. Screws, M6 x 25
  3. Charge-air cooler holder
  4. Screw, M6 x 60
  5. Screw, M6 x 30
  6. Bracket
  7. Screw, M6 x 25
  8. Collar nut, M6
  9. Coolant vent line
  10. Screw-type clamps on moulded hose
  11. Moulded hose
  1. Remove moulded hose -1  - for throttle housing.
    1. 1.1 Open screw-type clamps and pull off moulded hose.
    G14945753Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Disconnect vent lines and connecting hose for the ambient air valve.
    1. 2.1 Pull off plug-in couplings -2  -.
    2. 2.2 Open spring clamp -4  - and pull off hose.
    G14945754Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Release and disconnect cable plug -3  - on the boost pressure sensor -1  -.
    G14945755Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Pull off coolant hoses -1 and 2-  and vent line on the charge-air cooler.
    1. 4.1 Open spring band clamps -3  - and pull off coolant hoses.
    2. 4.2 Pull off vent line -4  - by pressing the locking lugs.
    G14945756Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Connect hose (sold by the metre, internal diameter approx. 16 mm) for blowing out coolant in the charge-air cooler.
    1. 5.1 Cut one short and one long piece of hose.
    2. 5.2 Connect short hose -1  - to the front connection piece.
    3. 5.3 Connect long hose -4  - to the connecting piece -3  - on the coolant hose and guide it into a collecting container (e.g. canister from special tool Filling device 9696).
    4. 5.4 Blow out residual coolant using a compressed-air gun -5  - (set the pressure to approx. 1 bar).
    G14945757Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Close off coolant openings.
  7. Loosen charge-air cooler -1  -.
    1. 7.1 Unscrew M6 screws -2  -.
    G14945758Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Loosen connection to the pressure pipe.
    1. 8.1 Open spring clamp -1  - and remove charge-air cooler by pulling it upwards.

      Check the installation position of the spring clamp! 

    2. 8.2 Re-fit spring clamp immediately.
    G14945759Courtesy of PORSCHE CARS NORTH AMERICA, INC.


Information 

  1. Coat coolant hoses with the prescribed lubricant.
  2. Insert charge-air cooler and connect it to the pressure pipe.

    The component must engage and must be seated securely! 

  3. Fit lines and hoses on the charge-air cooler.
  4. Install moulded hose for throttle housing.
  5. Fit and tighten M6 screws -2  - on the charge-air cooler -1  -.

    > Tightening torque 10 Nm 

    G14945760Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Tighten screw-type clamps -2  - on the moulded hose -1  -.

    > Tightening torque 5.5 Nm + 0.5 Nm 

    G14945761Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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