intake boot replacement

[dbleever]

> I am replacing the intake boots on a 1976 911S Porsche. I am having trouble getting the upper portion of the air box removed to expose the intake boot clamps. I have removed 11 screws that appear to secure the boxes upper and lower parts together.
>
> Are their other connectors that I have missed that hold the air box together. I have not removed the assembly containing the fuel distributor or the throttle body. It appears they connect to the top of the air box only.
>
> I do see one nut/stud back under the right side of the air box that appears to secures it to the motor, but nothing else that would preclude the removal of the top of the air box. Does the air box separate readily into two parts (upper& lower)?

Is there a better way to get to the clamps that secure the boots? It was suggested that I unbolt the intake manifolds from the heads, but access to those bolts would require removing heater blower assembly on the drivers side and the auxiliary air regulator on the passenger side.

Is it easier to pull the engine to get access to the these intake boots?

> Any help provided would be appreciated!! Thanks!

[al lkosmal]

It sounds like your trying to take the airbox apart, but I believe that the top and bottom are bonded together. The screws may have been used to hold it together, during bonding. (others will chime in, if I have this wrong). You don't need to drop the engine to do this, although it does make it easier. I suggest that you remove the entire intake assembly and replace the intake boots while the assembly is on your work bench. Then you can easily access the clamps, etc. When you re-assemble, just make sure that the intake flanges are positioned so that you can slip the flanges over the studs without twisting or bending too much. (You will have to have many of the inside most boot clamps tightened, prior to re-installing..I.e. the same problem you're experiencing now..they're hard or impossible to get at after installation)

I hope that is somewhat clear.

PS: yes...other stuff will have to be removed , as well...but I think that you will find it easier to do it this way...overall. It's about an 8 on the 1 to 10 PITA scale.

[Scott R]

First, stop trying to separate the airbox, it's glued together very well from the factory, it's likely you'll destroy the airbox doing this. Now on to the air boots, best way is to remove the CIS system from the car replace them on the bench and reinstall. There are plenty of threads on here on how to do that.

[Gunter]

Yep, it's a pain any which way.
I would leave the airbox alone, meaning: Do not take the airbox or FD ot TB apart.
A partial drop will help to get the complete CIS off.
If you need other work done like replacing the oil press. switch, thermostate gasket, breather gasket, etc.
Remove the extra fan blower and A/C compressor, disconnect the electr. harness.
That means disconnecting the alternator wires to slide them out of the shroud.
To reach the 13? mm nuts on the intake flanges, a swivel socket and long extensions will do it. Use new intake gaskets.
Some people have done it piece by piece without removing the complete CIS; it can be done.
You would have to work your way in by removing the runners one by one on one side and then do the same on the other side. It takes a lot of twisting and wiggling and cursing.