Intercooler upgrade to 2006 CTTS or FVD Brombacher kit (same intercoolers)

[DrumJoel]

Hello, I was able to get my hands on a set of the AKG intercoolers from a 2006 Turbo S. I made a guide on how to do this upgrade so that it may help others. Good luck, Joel 

 

955IntercoolerUpgrade.pdf

Edited April 9, 2020 by DrumJoel
I had completed the document before I put my bumper cover on. When I tried to put my car back together I found that the front air ducts my procedure was using didn't actually fit the 955 bumper cover so I had to correct my document to use the 955 ducts.

[GSpence2]

Nice write up. The T-clamps are they 3" , or 2" clamps ?

[DrumJoel]

Thank you GSpence2, are used some 2”-2.25” clamps. They ended up being a bit longer (thread wise) than I wanted but the extra bolt length didn’t end up hitting or interfering with anything so I didn’t trim them. Thanks, Joel

[GSpence2]

Nice I'll let you know how it goes. I've been wanting to do this since I had my engine rebuilt a few years ago. Bad scoring and piston slapped warranted a rebuild. parts on order. stay tuned...

 

[GSpence2]

Follow up 

Okay so AKG Intercoolers installed

Getting the correct pressure pipes and hoses from Porsche was a pain in the arse because the parts manager couldn’t get it through his head I wanted parts that didn’t necessarily match my VIN #
Took 3 tries and a week in delays 

After getting parts sorted and everything square I have noticed smoother boost and a big bump at 3200-4000RPM (stays solid at .7 bar)

BUT...

Now I’m chasing intermittent O2 issues

Alternating too lean or too rich on booth banks

I will pull some live data to compare duty cycles-on/off behavior on boost off boost to see if there’s any correlation 

[DrumJoel]

The install is great news GSpence2, i’m sorry to hear about your O2 issues. Hopefully you’ll get them resolved soon. I did the intercooler upgrade at the same time as a tune so I couldn’t tell who the real boost hero there is. I'm guessing both because the car pegs the boost at .8  at WOT every time now which would be the tune but it holds it well thanks to those big intercoolers. Good luck and please keep us posted. Joel

Edited June 2, 2020 by DrumJoel

[GSpence2]

Will do Joel. Thank you again for the suggestion. I suspect the O2 issues are old frayed harnesses. We shall see 👀

[GSpence2]

Update!

Actually solved the problem a while ago and forgot to post. So turns out the failing O2s were actually failing fuel pumps. 

I asked my shop who had rebuilt my engine after I burned it up to do some fuel pressure and volume tests after I got some really concerning live data on the Durametric during tests drives. The live data was showing under load - even light loads - I was running super lean and then when getting in the throttle I would load up and then off the throttle it was instant too rich and snap crackle pop what’s that smell??? My Pig sounded like a poorly tuned Maserati with a fart pipe.
Under the hood we go and sure enough instead of maintaining a solid 4-4.2 bar my fuel pumps were starting out at 3-bar and dropping down to 2-2.3 bar at WOT hence the hesitation big gulp of air that the ECU couldn’t compensate for check engine light let of the pedal throttle slams shut and snap crackle pop bang smell all that raw fuel?

So the injectors and O2s I figured were good 48lb. Bosch units that were installed when the rebuild was done so only other thing to double check was the ECU itself and the fuel pumps.

So instead of pulling the ECU sending it out and waiting we tested the fuel pumps straight away and therein lied the culprit. Man they were weaker than my stream at 2AM after a hard romp with the side chick (don’t tell my wife).

In with the new pumps and filter and voila!!! The Pig is an angry wild sow again! 
After doing the intercoolers and fuel pumps I had the motor retuned again and man it’s torquey. Smooth as silk too. I regularly break my rears loose at WOT in 2nd and the up shift to 3rd.
But honestly now I’m getting older and soft and it’s not as much fun anymore. The jolt really messes with my arthritis...

So I think next project will be some bigger brakes on this beast and then I’ll let it go. Maybe one of the kids will enjoy it. We just got a Panamera e-Hybrid for our daughter and she digs it. I like it too but she won’t trade. I even offered my 996TT to sweeten the deal but she won’t budge.

**** kids...