Installing Lower Part Of Intake Manifold With Fuel Distributor

→ Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.

→ Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.

→ Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.

→ Only install clean parts. Do not take spare parts out of the packaging until just before installation.

→ Never use compressed air when the system is open. Do not move the vehicle.

Information 

For tightening torques, tightening sequence and assembly overview, see → 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS

Information 

• Replace seals and O-rings  .
• Lightly lubricate O-rings for fuel injectors with clean engine oil  .

Information 

• Mark installation position of baffle plates before removal  .
• Install baffle plates at the correct installation position again following removal  .

1. Installation is performed in reverse order. Pay particular attention to the following:
2. The intake manifold flaps must be moved -in direction of arrow-  when installing the lower part of the intake manifold.
   Fig 1: Installing Intake Manifold Flaps

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Connect a hand vacuum pump.
   1. 3.1. Connect a hand vacuum pump to the connector on the vacuum actuator for intake manifold flap control as shown.

      Information 

      If the intake manifold flaps will not be opened, the flaps can be clamped with the guide plates in the cylinder head when installing the lower part of the intake manifold.

   2. 3.2. Create a vacuum using the hand vacuum pump -VAS 6213-  .
      Fig 2: Fitting Vacuum Pump On Intake Manifold Flaps

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Press lower part of intake manifold evenly onto the fuel injectors.
5. Tighten screws and nuts for lower part of intake manifold in diagonally opposite sequence to the specified torque. → 1001IN TIGHTENING TORQUES FOR ENGINE
6. Pull hand vacuum pump off the connection on the vacuum actuator for intake manifold flap control.
7. Install lower part of intake manifold.
   1. 7.1. Fit electric plug connection -4-  onto the fuel pressure sensor.
   2. 7.2. Tighten union nut -1-  . Counter at the screw socket while doing this.
   3. 7.3. For tightening torque, see assembly overview for lower part of intake manifold. → 1001IN TIGHTENING TORQUES FOR ENGINE
   4. 7.4. Check that the high-pressure fuel line is not strained.
      Fig 3: Installing Lower Part Of Intake Manifold

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.