Installing Intake-Air Distributor, Side 4-6

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Information

Always replace gaskets and O-rings.

Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68).

Information

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

Torx screws: (E..) for external Torx, (T..) for internal Torx.
Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)

Prepare intake-air distributor for installation.
1. 1.1. Clean sealing surfaces on the intake-air distributor and crankcase.
2. 1.2. Fit new molded seals on the intake-air distributor. Then grease them with Kluber Syntheso Glep.
  
  Fig 1: Fitting Intake-Air Distributor Seals
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Prepare fuel collection pipe with fuel injectors for installation.
1. 2.1. Fit new O-rings on fuel injectors. Grease O-rings lightly with VP 881 (Porsche Part No.: 000.043.207.35).
2. 2.2. Fit fuel injectors into the fuel collection pipe according to the marking and secure them with spring clamps.
Install intake-air distributor on side 4-6 -1- .
Use a bar magnet to fit hidden screws and a 5-mm socket-wrench insert with a ball joint to tighten them.
1. 3.1. Guide in the right intake-air distributor, turn it slightly and fit it on the cylinder head. Then fit and tighten screws.
  → Tightening torque: 10 Nm (7.5 ft. lb.)
  
  Fig 2: Installing Intake-Air Distributor (Side 4-6)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install fuel collection pipe with fuel injectors on side 4-6.
1. 4.1. Position the fuel collection pipe -2- with fuel injectors in the intake-air distributor.
2. 4.2. Fit and tighten two external Torx screws (E10, M6 x 12) -13- .
  → Tightening torque: 10 Nm (7.5 ft. lb.)
  
  Fig 3: Identifying Fuel Injectors Cylinders 4-6
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit fuel lines.
1. 5.1. Screw union nut on fuel line (a/f 19) -1- onto the fuel collection pipe and tighten it. Always counter while doing this (a/f 17).
  → Tightening torque: 30 Nm (22 ft. lb.)
2. 5.2. Screw the fuel line -2- onto the pressure regulator and tighten it. Counter at the pressure regulator while doing this (a/f 22).
  → Tightening torque: 30 Nm (22 ft. lb.)
  
  Fig 4: Identifying Fuel Collection Pipe And Fuel Lines (Side 4-6)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit the cable guide.
1. 6.1. Connect cable plug to the fuel injectors 4-6.
2. 6.2. Connect cable plug for ignition coil on cylinder 4 -1- .
3. 6.3. Connect cable plug -2- for hall sender.
4. 6.4. Clip on cable guide at the fuel collection pipe -arrow- .
  
  Fig 5: Installing Cable Rail And Cable Plug (Side 4-6)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit the engine wire harness and secure with a tie-wrap.
1. 7.1. Connect engine wire harness. Fit round connector onto connector bracket and turn clockwise until it reaches the locking point.
  
  Fig 6: Identifying Engine Wire Harness Round Connectors
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 7.2. Secure engine wire harness with a tie-wrap -arrow- .
  
  Fig 7: Locating Engine Wire Harness
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install holder -1- for oil filler neck.
1. 8.1. Insert holder and fit internal Torx screw (T27, M6 x 12) -2- at the bottom.
  → Tightening torque: 10 Nm (7.5 ft. lb.)
2. 8.2. Fit internal Torx screw (T27, M6 x 12) -2- at the top.
3. 8.3. Tighten both screws.
  → Tightening torque: 10 Nm (7.5 ft. lb.)
4. 8.4. Insert oil filler neck and close the holder.
  
  Fig 8: Identifying Oil Filler Neck Holder
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit air-conditioning compressor.
→ 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR .
1. 9.1. Fit compressor. Fit and tighten three M8 screws -5- .
  → Tightening torque: 23 Nm (17 ft. lb.)
2. 9.2. Fit and tighten fuel lines -4- on the fuel cooler. Counter at the fuel cooler (a/f 14) when tightening the union nuts.
  → Tightening torque: 25 Nm (19 ft. lb.)
  
  Fig 9: Tightening Air-Conditioning Compressor Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 9.3. Insert engine compartment temperature sensor -1- into the rubber holder.
  
  Fig 10: Inserting Engine Compartment Temperature Sensor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 9.4. Secure the fuel line -2- with an external Torx screw (E10, M6 x 12).
  → Tightening torque: 10 Nm (7.5 ft. lb.)
  
  Fig 11: Identifying Fuel Line
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.