996 Turbo - Intercooler Removal DIY w/pics
Discussion
Evening all, I was going to post this up as a response to another thread but then decided it was probably worth a thread of it’s own. A simple enough job but you never know, someone may find it useful.. So, rusty spanners and oily rags at the ready, here we go...
996 Turbo Intercooler Removal
First of all, remove rear bumper...
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
Then...
Tools you will need:
13mm socket
Torx 30 bit
Socket suitably sized for hose clips, can’t remember original size as I’ve replaced mine with stainless ones (you could use a screwdriver but this is generally a crap idea)
First remove the spring clip from the I/C end of the I/C to Y-pipe hose (top hose). Note, not strictly necessary but it makes refitting easier if you remove the top hoses completely. Next, remove the turbo to I/C hose (hose clip and spring clip.
Then remove the two 13mm nuts securing the side exhaust heat shield to the I/C bracket and free the heat shield from the studs and remove the TX30 screw securing the rear exhaust heat shield to the I/C bracket.
Remove the two 13mm nuts and three 13mm bolts securing the I/C bracket to the car, the I/C assembly can then be lifted free of car.
Once the I/C, still attached to bracket, is removed it is simply a case of removing the I/C complete with plastic ducting from its 4 rubber bushed locating points in the bracket and then popping open the spring clips holding the two halves of ducting together.
Once again, refitting is the reverse of removal
Finally, it’s worth noting that when refitting, ensure the I/C outlet on the end tank lines up exactly with the hole in the rear wing, either that or don’t fully tighten the nuts/bolts until you have the top hose fully secured in place. This give some scope for jiggling/lining up to ensure nothing is catching/snagged before fully tightening.
Have fun...
996 Turbo Intercooler Removal
First of all, remove rear bumper...
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
Then...
Tools you will need:
13mm socket
Torx 30 bit
Socket suitably sized for hose clips, can’t remember original size as I’ve replaced mine with stainless ones (you could use a screwdriver but this is generally a crap idea)
First remove the spring clip from the I/C end of the I/C to Y-pipe hose (top hose). Note, not strictly necessary but it makes refitting easier if you remove the top hoses completely. Next, remove the turbo to I/C hose (hose clip and spring clip.
Then remove the two 13mm nuts securing the side exhaust heat shield to the I/C bracket and free the heat shield from the studs and remove the TX30 screw securing the rear exhaust heat shield to the I/C bracket.
Remove the two 13mm nuts and three 13mm bolts securing the I/C bracket to the car, the I/C assembly can then be lifted free of car.
Once the I/C, still attached to bracket, is removed it is simply a case of removing the I/C complete with plastic ducting from its 4 rubber bushed locating points in the bracket and then popping open the spring clips holding the two halves of ducting together.
Once again, refitting is the reverse of removal
Finally, it’s worth noting that when refitting, ensure the I/C outlet on the end tank lines up exactly with the hole in the rear wing, either that or don’t fully tighten the nuts/bolts until you have the top hose fully secured in place. This give some scope for jiggling/lining up to ensure nothing is catching/snagged before fully tightening.
Have fun...
Edited by EvoSlayer on Thursday 24th February 20:36
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