Intercooler removal 87' 911 Turbo

[Larswik]

Sorry for all the questions, I just don't want to screw anything up first time under the engine.

I have 3 Porsche books 2 by Wayne and one by Bruce Anderson and none of them address Intercoolers in detail (removal or installation). I need to remove it to better access the fuel filter to replace it.

Here are my photos.
http://www.sbtraveler.tv/porsche/bolts1.jpg
http://www.sbtraveler.tv/porsche/bolts2.jpg

There seem to be 3 bolts and a couple of hoses that I need to detach from a visual inspection to remove it, is this right? also when I re attach it must I replace any o-rings or other parts with new ones? How hard should I torque the bolts on when I replace it again?

Can anyone outline in steps the removal and installation on the intercooler or link me to a page that details it?

Thanks!!!!

-Lars

[slodave]

No hoses going to the intercooler have fluid in them. If the bolts look like they are holding the intercooler to the engine, they gotta come off.

[Noah930]

Can't recall the torque specs on the intercooler, but it's a truly straightforward process. Just take off the few bolts holding stuff in place. Installation really is the reverse of removal. No new o-rings necessary.

[Larswik]

Thanks! in a last post I mentioned my exhaust smoking problem and someone responded to check the intercooler too for moister or something that might also be causing the problem. Will that be noticeable when I take it a part??

-Lars

[RarlyL8]

Removing the intercooler is not difficult.

Here is how I do it:
- Losten the hoses and pop them off.
- Loosten the 2 bolts and 2 hex head studs holding it down.
- Remove the 2 nuts on the bracket near the up-pipe.
- Remove the bolt and hardware near the throttle body.
**Capture the grommet and washers**
- Remove the bolt and hardware on the left side post.
**Capture the grommet and washers**
- The intercooler is now free. Wiggle it in 4 directions to gently dislodge the seal of the 2 O-rings. These are located on the throttle body and the up-pipe.
- Remove the intercooler and place it on a towel to protect the rubber trim and so nothing falls into the open ends. I jam a wad of rags into the throttle body and the up-pipe so nothing falls on there.

You will see an oil residue in the intercooler. That is normal. A LOT of oil is not.

Here are a few random pictures that show these things.

[Larswik]

Thanks for the photos. That is what I needed to see and hear. It does seem basic so I don;t understand why Wayne dosen't include this in his Projects 101 book?

-Lars

[spuggy]

Hey Lars,

Why are you dismantling the car?

Like several people told you in the 911 tech thread, the video you posted shows the temperature gauge on the bottom stop and the photo you posted showed oil on the stick in the normal range.

You can't check the oil level until the oil is up to temp, a correctly-filled 911 will have no oil showing on the stick when it's as cold as your video shows. It's probably good practice to run a 930 with slightly less oil than completely topped off anyway, as it expands when it gets hot - so "full" for highway driving and "too full" after 10-15 minutes in traffic with minimal/no air circulation over the front oil cooler are the same thing.

Here's the obligatory gauge decoder ring:



At the very least, you need to warm the car up before checking the oil. I'd be very inclined to dump all the oil, provide a fresh fill of 10 quarts and a filter, drive it until the oil is full operating temp (180-190 degrees), top off to the "correct" level and see if it is still smoking.

Alternatively, have fun dismantling your car.

[Larswik]

That is the goal to change the oil, filter and fuel filter since the Gas that is in the car has been there for 3 years now. I drained the fuel and put a fresh 5 gallons of Cheveron super unleaded. I don't want to dismantle the car but in order to gain access to the fuel filter I have to remove the intercooler (it's to tight for me). I would rather not do this but it will make it easier.

This last week I got all the parts, oil and so on for today's mission!.

-Lars