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Intake Manifold Removal
 
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Pelican Technical Article:

Intake Manifold Removal

Jared Fenton

Time:

3 hours3 hrs

Tab:

$100

Talent:

****

Tools:

T40 Torx Driver, 17mm 19m wrench

Applicable Models:

Porsche 955 Cayenne (2004-10)
Porsche 955 Cayenne GTS (2008-10)
Porsche 955 Cayenne S (2003-10)
Porsche 955 Cayenne Turbo (2003-10)
Porsche 955 Cayenne Turbo S (2006-10)

Parts Required:

New intake manifold gaskets, throttle body seal

Hot Tip:

Use a U-joint and extension to reach the rear bolt

Performance Gain:

Access to components below the intake manifold

Complementary Modification:

Replace starter

There are a few jobs on the Porsche Cayenne that require removal of the intake manifold for access to items below, such as the starter or the thermostat. In this article I'll go over the steps involved with removing the intake manifold.

Begin by removing the engine compartment covers (See our article on Removing Engine Covers) and then the air intake hoses and throttle body (See our article on Throttle Body Replacement for more information). Next remove the coil pack covers (See our article on Spark Plug and Coil Pack replacement for more information).

Removing the throttle body isn't technically required for the job; however, I find that it helps to do so. You'll have better access to remove the air hoses and to the valve covers as well as the wiring at the front of the manifold. You'll also need to relieve fuel pressure in the system. (See our article on Fuel Injector Replacement for more information).

When re-installing the manifold, replace the two intake manifold gaskets along the bottom and also the throttle body gasket. Once the manifold is in place, thread down each bolt individually. You'll want to make sure that the gaskets are sitting flat on the cylinder heads. Torqueing the intake manifold down is a two-stage process. That means that you will tighten each bolt in a crisscross manner once for the initial torque and then re-torque each bolt in the same manner to the final torque. The first stage is to 10Nm (7.5 ft./lbs.) and the second is to 15Nm (11 ft./lbs.).

After you have relieved the pressure in the fuel line, disconnect the fuel rail from the supply line.
Figure 1

After you have relieved the pressure in the fuel line, disconnect the fuel rail from the supply line. Use a 19mm wrench to hold the outer, hard line (yellow arrow) while you use a 17mm wrench to turn the fitting counter-clockwise (green arrow). Do not turn the outer line, just the inside one. Place a rag directly under the connection as you're likely to have some fuel spill out.

Remove the air hose connection from the left valve cover (green arrow) and also open up the plastic clamp holding the air line to the right side valve cover (yellow arrow.
Figure 2

Remove the air hose connection from the left valve cover (green arrow) and also open up the plastic clamp holding the air line to the right side valve cover (yellow arrow.

Now remove the air hose connection from the right valve cover.
Figure 3

Now remove the air hose connection from the right valve cover. Remove the hose connection by pressing the thick, ribbed tabs on either side of the connection (green arrow) and pulling it up and off the port.

Remove the air hose connector on the front of the right valve cover.
Figure 4

Remove the air hose connector on the front of the right valve cover.

Now remove the air hose connection to the port on the top of the intake manifold (blue arrow).
Figure 5

Now remove the air hose connection to the port on the top of the intake manifold (blue arrow).

Loosen each T40 bolt holding the intake manifold to the engine (yellow arrows) The bolts are held captive in the manifold, so don't worry about pulling them out, just loosen them.
Figure 6

Loosen each T40 bolt holding the intake manifold to the engine (yellow arrows) The bolts are held captive in the manifold, so don't worry about pulling them out, just loosen them. You'll also want to remove the electrical connector to each fuel injector (green arrows). Simply push the metal clip inward and pull the connector off. You may find it easier to remove a few after you lift the intake manifold up a bit.

The rearmost T40 Torx bolt is always a pain to remove.
Figure 7

The rearmost T40 Torx bolt is always a pain to remove. A combination of a u-joint, 3/8" drive extension and gently moving the air hoses helps to access this bolt.

Lift the manifold up and towards the front of the car enough to access the vacuum and air hose connections at the rear.
Figure 8

Lift the manifold up and towards the front of the car enough to access the vacuum and air hose connections at the rear.

Shown here is a close-up of the air hose connection at the rear of the manifold.
Figure 9

Shown here is a close-up of the air hose connection at the rear of the manifold. Squeeze the tabs on either side of the connector (green arrows). And pull the connector off. Also pull the vacuum hose off the manifold directly behind the air hose connector. Now carefully lift the manifold up and off the engine.  (You may also remove the vacuum connection from the other end where it goes to the firewall IF you think the connector in the picture is too difficult to access OR you cannot see how to properly disconnect it)

Turn the intake manifold upside down and remove the two gaskets at the bottom.
Figure 10

Turn the intake manifold upside down and remove the two gaskets at the bottom. You'll need to replace these with new intake manifold gaskets.

Shown here is the engine with the intake manifold removed.
Figure 11

Shown here is the engine with the intake manifold removed. It's a good idea to stuff rags or paper towels down each intake port. This prevents dirt or other foreign debris from entering the engine.

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Comments and Suggestions:
LEE Comments: how much torque to tight when we put back the intake manifold? Thanks
July 5, 2017
  Followup from the Pelican Staff: I don’t have torque information.

I would suggest you grab a repair manual, you should own one. It will have the procedure, special tools and torque specs.

Give our parts specialists a call at 1-888-280-7799.
- Nick at Pelican Parts
 
Sasquatch Comments: Do you sell the Intake Manifold bolts? How do I replace a broken CTT Intake Manifold Bolt? I was too Sasquatch & broke the rear driver's side intake manifold bolt. I was able to remove the remains of the bolt sticking inside the aluminum block/head with a vice-grip & chased out the threads with an M7 Tap. However, the Tap bottoms about 1/8" to 1/4" compared to the passenger side bolts. Should I force the Tap another 1/8-1/4" deeper into the hole?
April 15, 2017
  Followup from the Pelican Staff: Yes, Pelican can get them for you. Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
Matt Comments: PLEASE FIX YOUR WRITEUP. On figure 9, it says: "Also pull the vacuum hose off the manifold directly behind the air hose connector. "

You do NOT, I repeat, NOT pull the vacuum hose "off the manifold" - you carefully, with a flathead screwdriver to get you started, slide the hose that is attached that point you are instructing to pull from, but you slide it off the HARD LINE that goes into the firewall. NOT FROM THE MANIFOLD.

Ask me how I know? I just did what you instructions said and it instantly snapped off the male fitting which is part of the intake manifold, and is now stuck in the vacuum hose. That by itself is insignificant, but the manifold is now completely useless as that plastic male fitting has broken clean off.

Yes, I am ticked about this. Please make sure, if you are going to have DIY up here, that they are correct. Now I have to go find a $550 intake manifold for a 955...
March 19, 2017
  Followup from the Pelican Staff: Hey Matt, sorry to hear about your mishap. Truth is I have done quite a few intake manifold removals, and I have removed the fitting as described here without a single incident. As we all know these plastic pieces get weakened over time and we do appreciate your tip since it may help others. One of the things I love about working on my own car is that we have the control of how we work on things and no two mechanics do one job EXACTLY the same. It is up to us to be careful and to know when a certain approach may not be the best for the given situation. Your tip here HAS added a bit of value to our article and we appreciate it. - Casey at Pelican Parts  
Yagura6120 Comments: Nick, thank you for your suggestion. Checked all plugs and found cylinder#8 show white while others were black with more carbon. OBD indicated multiple misfire but always #8 exist with other random misfire. Disassemble Intake manifold and found #8 Gasket had problem due to limited space. There should be Air leak. Assemble again carefully and finally solved it. 😀
March 19, 2017
  Followup from the Pelican Staff: Awesome, thanks for the follow up. - Nick at Pelican Parts  
Yagura6120 Comments: I did Coolant hose maintenance then put it together again.
For Fuel rail, I did purge for both rail to remove Air in the Fuel rail. But when I tried to start engine, idling is very unstable and had misfire very badly. Keep run engine about 15 min but still not recovered yet.
Does anyone know something trick for it? Or I just need to have time for recovery?
March 4, 2017
  Followup from the Pelican Staff: You may have something connected wrong or an air leak. Double check your work. - Nick at Pelican Parts  
revoplanet Comments: I'm about to take out the intake manifold on my 2006 Cayenne Turbo. I have been looking around and saw this! What IS this stuff? Seepage of some kind? I bought it from someone a few years back and they seemed to have taken good care of it. Not sure what I'm looking at. Any idea?
January 15, 2017
  Followup from the Pelican Staff: Looks like coolant to me. I would assume there is or was a coolant leak. I would pressure test the cooling system to be sure. - Nick at Pelican Parts  
Phil Comments: iPad screen keeps jumping
November 19, 2016
  Followup from the Pelican Staff: Thanks for the info. I'll let the web team know. - Nick at Pelican Parts  
Cayenne Turbo 2005 Comments: @ben When I took my intake off, I left this hose on which is connected to the bottom of the throttle body and another hose to a vacuum. These are easier to remove and then take the hose off once you have the intake off. Otherwise yes, just squeeze the tabs and pull down and it should release from the nipple.
September 26, 2016
  Followup from the Pelican Staff: Thanks for the input on this one. We appreciate the help.
- Nick at Pelican Parts
 
ben Comments: Anyone know any tricks to getting the vacuum fitting at the back of the intake manifold in fig. 9 off? I can't for the life of me get it. The little collar with the squeeze tabs is loose and free to slide up and down but the hose will not come off. Should i try to re-engage the collar?
September 17, 2016
  Followup from the Pelican Staff: Ben a member said: When I took my intake off, I left this hose on which is connected to the bottom of the throttle body and another hose to a vacuum. These are easier to remove and then take the hose off once you have the intake off. Otherwise yes, just squeeze the tabs and pull down and it should release from the nipple. - Nick at Pelican Parts  
Cayenne Turbo 2005 Comments: Thanks Pelican Parts. Not only did I save nearly $1000 on parts, but I also was able to perform all the work saving a total of $3600 by using this website.
September 12, 2016
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it.
- Nick at Pelican Parts
 
Kenny Comments: Help please!! I'm in the middle of a starter replacement on a 2004 Cayenne Turbo. When removing the intake manifold I accidentally broke a plastic tee that connected to a hard plastic line. Top yellow circle in picture. Dealer says I have to buy an entire new line. I call BS! I only lost 1/4" from cutting out broken tee, and want to just get a metal tee to replace broken one. ALSO, I noticed a white plastic inline connector once intake manifold was removed that I can't tell what it went to. I believe all other connections are accounted for. Your advice/help is greatly appreciated.
July 26, 2016
  Followup from the Pelican Staff: I don't think that connector is from the factory. I would replace the broken and hose and whatever that connector was on.
Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.


- Nick at Pelican Parts
 
octaviolazo@sbcglobal.net Comments: Hi Nick, What is CUDA cleaner?
June 11, 2016
  Followup from the Pelican Staff: A hot water parts cleaner.

http://www.cudausa.com /- Nick at Pelican Parts
 
Lazo Comments: Can anyone tell me where I can take the intake manifold on a 2003 Porsche Cayenne S to get cleaned. I just replace the water pump valve cover gasket spark plugs and I do not want to put back the intake manifold as dirty as it is now.
June 5, 2016
  Followup from the Pelican Staff: Try a local shop. Ask for someone with a CUDA cleaner. - Nick at Pelican Parts  
burrjf Comments: To remove the starter without taking out the cooling tubes, loosen the three rear screws at the rear of tubes on the bracket. This will allow you a couple mm more clearance to remove the starter.
May 25, 2016
  Followup from the Pelican Staff: Thanks for the additional info. We appreciate it.
- Nick at Pelican Parts
 
lporsche Comments: I'm in need of help for changing my steering pump..thanks
September 20, 2015
  Followup from the Pelican Staff: The pump is removed from below on V6 models. - Nick at Pelican Parts  
steve Comments: Hi ...do you have a clue on how to get easier to the steering pump...thanks
September 20, 2015
  Followup from the Pelican Staff: The pump is removed from below on V6 models. - Nick at Pelican Parts  
Alex Comments: Hi, do you have a write up for the cayenne 3.6 V6 replacement? Should I look in the touareg section?
July 9, 2015
  Followup from the Pelican Staff: We don't currently have that tech article. If we get a chance to perform the procedure, we will be sure to document it.

I would grab a repair manual. It will have the procedure, special tools and torque specs.

Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
Cove Comments: It is the semi flexible pipe that one of its connection is under the y pipe up front. The pic shows the connector with the push tabs slid down and the red gasket part exposed.
February 9, 2015
  Followup from the Pelican Staff: Yes that part works with the braking system and if the locking connection is broken it needs to be replaced. To get that off you will need to carefully split the plastic layers of the connector away from the delicate nipple on the intake. I'd recommend removing the manifold with that piece still connected and then using a dremmel to cut in to and peel the layers of the connector away from the nipple until the pipe can be delicately removed.


Part number is 94811007003 in case you need to replace it.

=0
- Casey at Pelican Parts
 
Cove Comments: I am in the process of removing the manifold on a 2005 Porsche Cayenne S and the squeeze connector has seperated and I can't seem to get the connector to come off the manifold. Any suggestions?
February 7, 2015
  Followup from the Pelican Staff: I am not sure which connector you are speaking of. Is this the vacuum line back by the firewall on the passenger side of the intake manifold? If you're speaking of this one it can be a real pain... you may be better off cutting the connector off and replacing the hose because this is for the vacuum booster and could affect braking if it does not seal or hold properly to the manifold. Do not risk a safety issue. Please reply with a photo so I can see the connector and location. - Casey at Pelican Parts  

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Page last updated: Mon 7/24/2017 02:38:05 AM