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Intake Manifold Replacement
 
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Pelican Technical Article:

Intake Manifold Replacement

Steve Vernon

Time:

2 hours2 hrs

Tab:

$16 to $80

Talent:

**

Tools:

Flathead screwdriver, 10mm wrench, punch, 6mm, 5mm Allen

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

Intake gaskets

Hot Tip:

Tap the manifold with a rubber mallet to free it up

Performance Gain:

Access to other systems

Complementary Modification:

Clean the throttle body

If you own a Porsche 951 and plan on doing any work on the turbo, idler valve, AOS or vacuum lines, you will need to first remove the intake manifold. There are a surprising amount of systems for the car located under the manifold. Removing it is the only way to service or replace them.

You are going to be removing Allen head bolts from the engine. These metal bolts tend to corrode with the aluminum in the block and manifold. It is a good idea to use a punch and tap the inside of the bolt before attempting to remove it. This can help break the corrosion. Also make sure the Allen socket is completely seated in the bolt head. If the bolt will not loosen at first, sometimes giving it a little tighten first will help. Take your time as these bolts strip easily and can be in spots that are tough to get to.

You will need to first remove the fuel rail and injectors (red arrow).
Figure 1

You will need to first remove the fuel rail and injectors (red arrow). Please see our article on fuel rail and injector replacement. Be sure to follow all the precautions when working with fuel.

You will also need to use a flathead screwdriver and remove the two screws (red arrows) and the air intake to the air box, so you can get access to the intercooler to throttle body tube.
Figure 2

You will also need to use a flathead screwdriver and remove the two screws (red arrows) and the air intake to the air box, so you can get access to the intercooler to throttle body tube. Depending on the systems you will be working on you may want to remove the entire air box. If you do please see our article on air box removal.

Use a flathead screwdriver and remove the clamp on the tube to intercooler.
Figure 3

Use a flathead screwdriver and remove the clamp on the tube to intercooler. You will want to remove the tube completely and not just the rubber sleeve between the tube and throttle body, as you will need the remove it to remove the bolts. Disconnect the two hoses connected to the tube and remove the tube (red arrows).

Disconnect the throttle switch connection from the switch mounted on the throttle (red arrows).
Figure 4

Disconnect the throttle switch connection from the switch mounted on the throttle (red arrows). The switch will stay mounted to the throttle body when you remove it. Disconnect the vacuum hose from the bottom of the body (yellow arrow).

Use a 10mm wrench and remove the two bolts that hold the throttle cable to the intake manifold (red arrows).
Figure 5

Use a 10mm wrench and remove the two bolts that hold the throttle cable to the intake manifold (red arrows).

Next, remove the 10mm bolt holding the dipstick tube (red arrow) to the manifold.
Figure 6

Next, remove the 10mm bolt holding the dipstick tube (red arrow) to the manifold.

Use a 10mm wrench and remove the single bolt holding the oil dipstick tube to the manifold (red arrow).
Figure 7

Use a 10mm wrench and remove the single bolt holding the oil dipstick tube to the manifold (red arrow).

Use a punch first to gently tap the Allen head bolts.
Figure 8

Use a punch first to gently tap the Allen head bolts. Clean the head of the bolts and then make sure that the 5mm Allen socket is properly seated. Remove the two bolts on the rear of the manifold by the oil filler tube (red arrow).

Depending on the manifold you have you will have several vacuum lines (red arrow) and hoses attached to it.
Figure 9

Depending on the manifold you have you will have several vacuum lines (red arrow) and hoses attached to it. Use a flathead screwdriver and remove the two hose clamps and hoses from the manifold (yellow arrow).

Use a 13mm socket and remove the banjo bolt for the vacuum lines between the three and four intake runners (red arrow).
Figure 10

Use a 13mm socket and remove the banjo bolt for the vacuum lines between the three and four intake runners (red arrow).

Follow the steps for properly removing the Allen head bolts.
Figure 11

Follow the steps for properly removing the Allen head bolts. Using a 6mm Allen, remove the eight Allen head bolts on the manifold (red arrows).

The Allen bolt on the rear of the manifold is longer than the others due to the ground cable and clamp that the rear bolt passes through (red arrow).
Figure 12

The Allen bolt on the rear of the manifold is longer than the others due to the ground cable and clamp that the rear bolt passes through (red arrow). Do not mix these up when reinstalling.

If the manifold is stuck you can gently tap it with a rubber mallet.
Figure 13

If the manifold is stuck you can gently tap it with a rubber mallet. Remove the manifold (red arrow) from the motor. Make sure to remove the old gaskets and clean the mounting surfaces (yellow arrows).

You should always cover the intake ports right away (red arrows).
Figure 14

You should always cover the intake ports right away (red arrows). I like to stuff some rags in the ports and then tape over them. You do NOT want anything falling in these ports, as they go directly to the combustion chamber. You could end up having to remove the head to retrieve anything that falls in. Installation is the reverse of removal.

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