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Pelican Technical Article:

Crossover Pipe Removal

Steve Vernon

Time:

2 hours2 hrs

Tab:

$0

Talent:

**

Tools:

10mm socket, flathead screwdriver

Applicable Models:

Porsche 944 Turbo (1986-89)

Hot Tip:

Let the car cool before working on it

Performance Gain:

Access to other systems

Complementary Modification:

Coolant Flush

The Porsche 951 has a crossover pipe in front of the engine that serves several purposes. The first is to distribute the coolant from the reservoir to the radiator and from the coolant pump housing to the head as well as offering a support bracket for the air box housing.

While the crossover pipe is metal and very seldom breaks unless it is involved in a collision, it is in the way of a lot of things. You will find yourself wanting to or needing to remove it for a host of projects on the vehicle. This article will show you how.

You are going to need to drain the coolant to below the level of the pipe. Make sure the vehicle is cool to the touch and follow the instructions on our draining and bleeding your coolant article for additional assistance. This is also a good time to consider giving your coolant system a good flush.

This illustration shows the crossover pipe in orange.
Figure 1

This illustration shows the crossover pipe in orange. You can also see all of the coolant hoses in the diagram. If you have not inspected all of your hoses, this is a good time to do it.

The crossover pipe (red arrows) is located below the air box and turbo to intercooler and intercooler to intake manifold pipe.
Figure 2

The crossover pipe (red arrows) is located below the air box and turbo to intercooler and intercooler to intake manifold pipe. You will need to remove the air box and air pipes. Please see our article on air box removal for additional assistance. The large diameter section of the pipe will carry coolant from the reservoir (yellow arrow) over to the right side of the radiator.

With the air box removed you can see the crossover pipe (red arrow) as well as the bracket for the air box (yellow arrow).
Figure 3

With the air box removed you can see the crossover pipe (red arrow) as well as the bracket for the air box (yellow arrow). In this photo the intercooler to intake manifold pipe (green arrow) has not yet been removed. You will need to use a flathead screwdriver and remove the hoses attached to the pipe and remove the pipe from the engine bay.

Next, remove the fresh air to turbo supply side boot (red arrow) by using a flathead screwdriver and removing all the hoses attached to it.
Figure 4

Next, remove the fresh air to turbo supply side boot (red arrow) by using a flathead screwdriver and removing all the hoses attached to it. Then loosen the clamp connecting it to the turbo (yellow arrow) and remove the boot.

With the boot removed you can see the supply side of the crossover pipe.
Figure 5

With the boot removed you can see the supply side of the crossover pipe. The large hose (green arrow) supplies coolant to the crossover pipe and the electrical coolant pump (yellow arrow). Use a flathead screwdriver and separate the hose from the crossover pipe. In our case we are going to replace the hose, so we separated it from the coolant reservoir as well as the electrical coolant pump. Next, remove the clamp and then the hose that connects to the head (red arrow).

With everything disconnected use a 10mm socket and remove the two 10mm bolts holding the crossover pipe to the frame rails (red arrows).
Figure 6

With everything disconnected use a 10mm socket and remove the two 10mm bolts holding the crossover pipe to the frame rails (red arrows).

Working on the right side of the motor you can see the hose that connects from the crossover pipe to the radiator (red arrow).
Figure 7

Working on the right side of the motor you can see the hose that connects from the crossover pipe to the radiator (red arrow). This line is how the coolant flows from the reservoir to the radiator. Remove the clamp and hose to the radiator as well as the hose that connects to the coolant pump housing (yellow arrow).

Use a 10mm socket and remove the two bolts holding the right side of the crossover pipe to the frame rail (red arrows).
Figure 8

Use a 10mm socket and remove the two bolts holding the right side of the crossover pipe to the frame rail (red arrows). We have removed the distributor cap (yellow arrow) for another project. You do not need to remove it to remove the pipe.

You can now maneuver the pipe (red arrow) out from the engine area.
Figure 9

You can now maneuver the pipe (red arrow) out from the engine area.

With the pipe out of the vehicle you can see where the y-hose (red arrow) from the coolant reservoir connects to the crossover pipe and the electric pump (green arrow) as well as where it exits the crossover pipe on the right side (left in this picture, red arrow).
Figure 10

With the pipe out of the vehicle you can see where the "y-hose" (red arrow) from the coolant reservoir connects to the crossover pipe and the electric pump (green arrow) as well as where it exits the crossover pipe on the right side (left in this picture, red arrow). You can also see where the hoses from the coolant pump to head are attached (yellow arrows). Installation is the reverse of removal.

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