88 Carrera Intake R&R

[porschzilla]

Hi All,

I see from my fuel line post that the consensus is to remove the intake manifold. I only have the Bentley manual and it says squat on how to do this.
It is a lot different than a 67 GTO motor.
I really do not want to but if it is the only way to replace my fuel line I will have to. I never did a 911 so can someone please tell me how to? On top of 12 gaskets do I need new spacers too? Do I use a sealant? What do I use to clean off the old gasket? Is the bolt socket an 8mm allen? Is there a special torque down sequence? Is it a simple R&R or is there a breakdown or guidance that someone can please give me.

Thanks
Jack

1988 Carrera

[BReyes]

Yes it is different than doing simlar work on your GTO but should you go this route, if you have done lots of work on your goat this too is doable confidently.

Regards,

[rick-l]

Like I said in the other post I just removed the drivers side. It is pretty straightforward to remove just take out all the fuel injection stuff on top of the engine.

To clean the cylinder head where the intake mates is difficult because the fan shroud sits 1/2 inch above the mating surface so it takes a variety of tools to carefully scrape it (stick a rag into the opening). I tried Locktite gasket cleaner but it didn't work that well.

The forward cylinder (had the most gasket stuck on it of course) almost had to be done with a mirror.

[JeremyD]

It's pretty straight forward - although I have to admit the first time I jumped in I was a little intimidated because it looked so different from every other engine. But really it will all start making sense when you dig in. Just take lots of digital pictures from different angles - makes it easier to reassemble with references.

[aj88cab]

Jack

Remove the air filter box, AFM, rubber boot, & Throttle Body. Relieve the fuel pressure at the fitting on the left fuel rail (don't loose the ball!), disconnect the fuel line at the fuel filter, separate the fuel line at the fitting at the fuel damper (behind where the air box was). There are several vacuum lines including the brake booster vac line that need to be disconnected. Oh yeah, several electrical connectors too. You will probably find that the insulation on the three sensors (CHT, Speed, TDC) that connect on the left has/will crumble (your not alone).

Finally unbolt the manifold and remove each side separately. You don't really have to remove all the fuel injection stuff it just stays on the manifolds. But, while your in there you might as well replace the injector seals. There are probably a few more steps that I forgot but that's pretty much it. Cleaning the intake is a bit of a pain as rick-l mentioned. New gaskets and spacers, no sealant (at least I didn't). Reconnecting the springs on the throttle linkage was a bit of a pain, I used a long tie wrap to hook the springs and pull them to attach to the tab on the manifold (you'll understand when you're in there).

Good Luck

[porschzilla]

I have everything off of the intake. It is a little intimidating next to a V8.
I have gotten 2 stories one-I can just take off the bolts from the drivers side and one to remove the whole intake. If I just do the drivers side how much play is there ? Is there any?
Also what is the torque down on the bolts on the install. I just read that there are spacers between the gaskets? Do I have to go to Porsche and get for one side 6 gaskets and 3 spacers?
Thanks for all of your input.

Jack
1988 911 Carrera

[aj88cab]

The fuel line you are trying to replace will come off with the driver side manifold if you disconnect the lines as mentioned above. There are spacers with gaskets on each side. So, yes, 6 gaskets and 3 spacers.

[porschzilla]

Originally Posted by aj88cab

The fuel line you are trying to replace will come off with the driver side manifold if you disconnect the lines as mentioned above. There are spacers with gaskets on each side. So, yes, 6 gaskets and 3 spacers.

Andrew,

Thanks!!!
I just got the gaskets as they were in stock.
I was told by a Porsche mechanic that I should be able to reuse the spacers (if they aren't dried out) as I have little mileage on the motor regardless of age. (they weren't in stock)
I will lift the drivers side as that really seems to be the only way to replace the fuel line and I am uncomfortable with this as it is new territory for me. I have owned this car since new but I never worked on it. Now it is Porsche learning time.

Thanks again all
Jack

1988 911 Carrera Cabrio
1931 Ford Model A
1953 Jaguar XK120DHC
1963 Jaguar MKII
1967 Jaguar E-Type OTS
1967 Pontiac GTO Convertible
1961 Cadillac Convertible
1975 Cadillac Eldorado Convertible
2006 Dodge Magnum
1997 Jeep Grand Cherokee

[steely]

Guys - this is terrific stuff as I am in the middle of this myself.

Did you ever get answers to the questions regarding Bolt Torque (mine came off really easy!!?), and testing - will the pump pressurize the system for leak test without the engine ON?

BTW, I took pics, but have been slowed down by the removal of hw on the drivers side intake (cruise control, electrical harness running between the stacks, etc)

Thanks!

[aj88cab]

Intake manifold to cylinder head torque = 18 ft-lb (25Nm), from the Bentley manual.

[aj88cab]

Hey guys,

Just a thought...but if you have never replaced the oil thermostat o-ring, oil breather gasket, and the oil pressure sender...this would be a REALLY good time to do some preventive maintenance...just a thought.

[steely]

Thanks for thr torque and the advice on the gaskets and o-rings, aj88cab.
That is exactly what I am doing, not to mention the fuel lines.
I wasn't going to pursue the injector seals, but now since they're out.....