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Pelican Technical Article:

Intercooler Console Removal

Casey Gervig

Time:

15-20 Minutes

Tab:

$0

Talent:

*

Tools:

13mm socket, socket wrench, 7mm nut driver, T30 socket or driver, needle nosed pliers or small flat blade screwdriver

Applicable Models:

Porsche 996 GT2 (2002-05)
Porsche 996 Turbo (2001-05)
Porsche 996 Turbo S (2005)

Parts Required:

Fasteners

Hot Tip:

Clean off the intercooler shroud and cool air inlet while the console is off the car

Performance Gain:

More efficient cooling of compressed intake air

Complementary Modification:

Forge Motorsport Uprated Intercooler kit, or GT2 Intercooler upgrade

Intercoolers increase the efficiency of the induction system by reducing induction air heat created by the turbochargers and promoting more thorough combustion. This removes the heat of compression that occurs in the intake plumbing when it is pressurized. On the 996 Turbo and GT2, the intercooler console consists of the bracket, the intercooler, the cold air inlet duct, and the cold air outlet shroud. This article will cover removing one side. The process is the same for left and right side intercooler consoles.

Begin by removing the: engine air filter housing, rear bumper, rear portion of rear fender liner, and rear wheel.
Figure 1

Begin by removing the: engine air filter housing, rear bumper, rear portion of rear fender liner, and rear wheel. (See our articles on: Jacking up your 996, Rear fender liner removal, Engine air filter replacement, and 996 Turbo Rear Bumper Removal for instructions.) Then, working at the rear of the car, loosen this T30 heat shield screw (green arrow). These are "odd ball" screws and are only used in this position so keep track of these and remember their placement. Note the layering of the heat shields in this photo to help when you are reassembling the car.

Using pliers or a small flat blade screwdriver, remove the boost pipe-retaining clip (green arrow) from the intercooler outlet (yellow arrow).
Figure 2

Using pliers or a small flat blade screwdriver, remove the boost pipe-retaining clip (green arrow) from the intercooler outlet (yellow arrow). Then working from inside the engine compartment pull the hose until it is free from the intercooler outlet. (The inset photo shows the general location of the intercooler outlet.)

Working under the intercooler console, use your 7mm nut driver or screwdriver to loosen the hose clamp on the turbo outlet (green arrow), and pull the hose off of the turbo.
Figure 3

Working under the intercooler console, use your 7mm nut driver or screwdriver to loosen the hose clamp on the turbo outlet (green arrow), and pull the hose off of the turbo. While here I usually like to make sure that the two hose clamps for the turbo inlet (red arrows) are tight.

Remove these two 13mm nuts (green arrows), which hold the heat shield to the intercooler console.
Figure 4

Remove these two 13mm nuts (green arrows), which hold the heat shield to the intercooler console. Then pull the heat shield free from the studs. It will still be attached to the body frame rail up above, and that is fine for now. Just make sure that it is not going to hang up on the intercooler console when you pull it off of the car. 

Now we are ready to remove the console mounting hardware.
Figure 5

Now we are ready to remove the console mounting hardware. There are five fasteners that hold the intercooler console to the car. All are 13mm hex fasteners (three bolts and two nuts). I usually remove the three bolts (yellow arrows) first. Then the nuts (green arrows) the studs will usually hold the console up on the car once the nuts are removed. Then slide the console toward the front of the car (red arrow) to release it from the studs, and pull it off of the car.

Once the console is removed, (picture shows intercooler still mounted on car) use eye protection.
Figure 6

Once the console is removed, (picture shows intercooler still mounted on car) use eye protection. Blow compressed air through the intercooler fin outlet (yellow arrows) and watch what interesting stuff flies up out of the air inlet (green arrows). It's definitely a good idea to dump the console out by flipping it over. I once had a customer who had his son put seven Hot Wheels cars through the duct in the fender. They were all in sitting on top of the intercooler and came tumbling out of the intercooler when I flipped it over!

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