Kokeln Install Help for Lazy Person

[zakthor]

Dear Brain Trust,

I've got some free time and hoping to install my Kokeln intercooler into my perfectly drivable 79 930 with stock turbo.

I followed jwasburys thread. He had a lot of trouble because he started with the 965 kit so hopefully my install goes easier. But sure would help if I had all the right stuffs before I started taking things apart.

Great JWasbury thread:

Incoming! Kokeln I/C "charge air cooler" - questions on install

So anyhoo I (believe) have most of the parts I need but no extra hoses like in the kit pitchers.

In a perfect world someone on here with a kokeln and stock 930 would be able to just tell me exactly the sizes for the extra hoses and fittings I need. Ideally I just order the stuff and then plug it all in.

This other thread is pretty good, it has a picture of a Kokeln ad that shows the kit with hoses.

Porsche 930 intercooler advise

And there's this web page of someone doing exactly what I want to do:

https://members.rennlist.com/magisterc/kokeln.html

Squinting at the Kokeln ad it looks like I'm missing 2 x ~1" hoses, a long thin hose, a t-fitting and some bolts? And also a silicon o-ring for the base of the intercooler? Or do I steal that o-ring from my current intercooler?

I'd also appreciate if someone can give names to the various orifices on the intercoolers:


Holes on back of intercooler:



From left to right:
A: Input
B: I Dunno, has long thin tubing in install picture
C: Blocked Off with rubber plug: Overpressure?
D: I dunno

Front of intercooler:



E: big hole: output (reuse existing oring?)
F: mounting point

Front side (no picture):

Aux Air - Last picture of install thread shows where this goes:

https://members.rennlist.com/magisterc/kokeln.html

Rubber elbow:



G: Big: Input
H: Big: Output
I: Top Hole: Cut Off Valve

Cutoff Valve:



I: Bottom Hole: looks like it plugs into the top of the elbow (I, above)
J: Small tube in top: I dunno
K: Side hole: Vent to atmosphere?

Whats the plastic elbow thing for?

Adapter sleeve:



I think it plugs into the elbow.

Thanks all.

[Alan L]

I'm not familiar with your set up - but to kick things off;
Do you have two fittings on the IC with threads? because you have a boost gauge sender and an over boost switch threaded in to your stock unit. If you have two threaded holes, that accounts for two.
The rubber elbow; you can see the direction arrow - that is towards the turbo - where the arrow is that is the outlet. the short elbow piece goes on to the airplate outlet. the short neck poking up has to accomodate your recirc valve unit - I am guessing that is the piece in the plastic bag - see if the neck fits.
The small outlet tube on that recirc valve hooks on to a hose from your throttle body - you may have to T a piece in. It is on an outlet from the TB on the low side of the butterfly from memory .
You should be able to re use the big O ring on the TB - the IC has to fit this neck, so yes, use same O ring. When you mount it, don't expect it to all drop in place - will take a lot of jiggling maybe tweek turbo orientation etc. You also have a hose fitting somewhere that will hook on to the hose line that runs up front of the vehicle - LHS engine compartment - strong hose - runs to your brake booster. I am guessing it is the nipple fitting.
Hopes that kick starts for you.
Alan

[pdqcarrera]

My advice FWIW:
https://www.pcarshops.com/near/beaux-arts-wa
:-)

[pkabush]

Originally Posted by pdqcarrera

My advice FWIW:
https://www.pcarshops.com/near/beaux-arts-wa
:-)

Naw... he cannn dooo eeet. That’s what this board is all about. Right ?
Allen has you on the right path. Although, I’ve installed three different I/Cs and never had to run a line to the brake booster. Or perhaps I misread (I can’t scroll up to check)
and he was saying you can tap in to the booster line for the boost gauge sending unit if your I/C doesn’t have the appropriate sized threaded bung. If not, what I’ve done in the past is simply drill into the I/C with a stepped bit, tapped a hole and screwed it in with some sealer applied. Here’s a pic of one of mine.
The nipple on your recerc valve should be 1” Same as the opening in your 965 rubber elbow so, that should plug right in. Toss on a hose clamp, done. If the down pipe doesn’t work with an o-ring you can either use a silicone one from a 965 (spendy) or an appropriate sized silicone coupler and t-clamps at either end. IIRC Koklyn or perhaps it was B&B had a diagram on there website. In fact I think Chris from TC posted it here a few years back. Either way, I’ll see if I can find it. In the meantime feel free to PM me if you have any questions.

[zakthor]

Originally Posted by pkabush

Naw... he cannn dooo eeet. That’s what this board is all about. Right ?
Allen has you on the right path. Although, I’ve installed three different I/Cs and never had to run a line to the brake booster. Or perhaps I misread (I can’t scroll up to check)
and he was saying you can tap in to the booster line for the boost gauge sending unit if your I/C doesn’t have the appropriate sized threaded bung. If not, what I’ve done in the past is simply drill into the I/C with a stepped bit, tapped a hole and screwed it in with some sealer applied. Here’s a pic of one of mine.
The nipple on your recerc valve should be 1” Same as the opening in your 965 rubber elbow so, that should plug right in. Toss on a hose clamp, done. If the down pipe doesn’t work with an o-ring you can either use a silicone one from a 965 (spendy) or an appropriate sized silicone coupler and t-clamps at either end. IIRC Koklyn or perhaps it was B&B had a diagram on there website. In fact I think Chris from TC posted it here a few years back. Either way, I’ll see if I can find it. In the meantime feel free to PM me if you have any questions.

Thanks! I know I can do it. Just a question of how much I need to do wrong in order to find out what is right. Like those hose lengths.

Sure would be great to have a picture, or some instructions.

The silver thing in the bag, it goes into the top of my rubber elbow. This is a case of too many names:

https://www.pelicanparts.com/More_Info/990609100.htm?pn=99-0609-100-M285

Lindsey racing calls it a bypass valve but its called a cutoff valve by pelican and that's what it was called when I ordered it form pelican years ago, says it on the bag. Normally there is a plastic 90's turbo part that people use (993.110.337.51) but I got the aluminum version I think was made by/for Mode. It looks cool to me. Is this thing the same as what you're calling the 'recirc valve'?

[Alan L]

Correct - it replaces the original recirculation valve. Thats why it has the small nipple that has to hook on to a hose point (or T in) on the lower side of the butterfly. The charge in the turbo system has to be dumped when you get off the gas. The turbo is driven by exhaust gases - which drop off when you get off the gas. But you still have a high pressure in the inlet system from the turbo so the turbo is in danger of stalling against that. So the little hose picks up the vacuum below the butterfly when shut, and opens that valve - which dumps the excess pressure in to your intake elbow. So you have that part correct now - it fits the elbow. One down, a few more to go. Next job - see where you can run a line to the nipple on the dump/recirc/bypass/cut off valve.
Then see if you can find a thick hose on LHS of engine bay that used to hook on to a hose nipple on stock IC. The ID of the hose will be something between 1/4 and 3/8" at a guess.
Alan

[Manda Racing]

Not sure this helps. Send email addy if you want more.

[flightlead404]

Just go to Turbokraft's site and read the installation instructions for their long neck intercooler.

[timc]

Do a search, I installed mine (Kokeln) years ago, and i think I had a thread going on the install with questions and links....


tim

[zakthor]

Thanks Manda, great pictures. Is what I needed.

Thanks Tim, good threads i'd missed before:

Installing Kokeln Intercooler

Kokeln Intercooler Shroud

I'd forgotten about the shroud.

Now to call Mako to source some hose and clamps.

Originally Posted by timc

Do a search, I installed mine (Kokeln) years ago, and i think I had a thread going on the install with questions and links....


tim

[Alan L]

Not at my car right now - but I may have put you wrong on the hose/nipple bit. I think the brake boost hose comes off the inlet manifold - below the rubber elbow. The hose you are looking to hook on to the nipple comes from the W gate.
Alan

[Dominik 930]

here my friend, I just installed a kokeln, with the vacuum box (this must be installed so that the turbo gas take away, no oil sucks, the negative pressure is otherwise too big, says my engine builder). If you have any questions, you are welcome to contact me, I am glad to help you. greetings dominik