Installing intake distributor - Boxster S

Fig 1: Exploded View Of Intake Distributor (Manifold) Components (Boxster S)

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Installation overview: 

Fig 2: Installing Intake Distributor (Boxster S)

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1. Tightening fastening screws
2. Fitting vacuum lines
3. Tightening fuel line
4. Tightening fuel return line
5. Installing secondary air pump (USA vehicles only)
6. Installing tuning pipe
7. Installing throttle body
8. Closing maintenance cover
9. Installing passenger's seat

1. Tightening fastening screws

   Replace the seals on the intake distributor. Pay attention to the position of the lugs when doing this. Fit the intake manifolds with the fuel ring pipe and take the cloths out of the intake channels. Replace the micro-encapsulated screws on the intake system and tighten to 9.7 Nm (7 ftlb.).

   Fig 3: Replacing Seals On Intake Distributor (Boxster S)

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2. Fitting vacuum lines

   Put on the vacuum line to the brake booster with a new O-ring. Tighten the two fastening screws. Tighten the fastening screw of the bleeder valve for the carbon canister on the left intake manifold. Put on the crankcase vent on cylinder bank 1-3. Clip in the switch-over valve for the tuning flap.

   Fig 4: Tightening Fastening Screws On Vacuum Line (Boxster S)

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3. Tightening fuel line

   Tighten the screwed connection of the fuel line. Make sure to counter with an open-ended wrench when doing this. Check screwed connection for leaks.

   Fig 5: Tightening Screwed Connection Of Fuel Line At Fuel Pressure Regulator (Boxster S)

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4. Tightening fuel return line

   Tighten the screwed connection of the fuel return line. Then check the screwed connection for leaks.

   Fig 6: Tightening Fuel Return Line (Boxster S)

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5. Installing secondary air pump (USA vehicles only)

   Tighten the starter ground cable on the body. Open the spring band clamp using commercially available spring-band clamp pliers No. 72 or No. 73 and push it on. Tighten the three fastening screws on the secondary air pump to 9.7 Nm (7 ftlb.). Connect electrical connection.

   Fig 7: Installing Secondary Air Pump (Boxster S)

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6. Installing tuning pipe

   Move tuning pipe into installation position. Push the two rubber sleeves over the pipe and align. Align the tuning pipe so that the two arrows are lined up. Then tighten the four fastening screws and connect the vacuum lines to the vacuum modulator and the rubber sleeves.

   Fig 8: Installing Tuning Pipe (Boxster S)

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7. Installing throttle body

   Move throttle body into installation position. Push the two rubber sleeves over it and tighten the four hose clamps. Push on the connector tube between the air cleaner and the throttle, and tighten the hose clamp. Tighten the fastening nuts to 9.7 Nm (7 ftlb.).

   Fig 9: Installing Throttle Body (Boxster S)

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8. Closing maintenance cover

   Tighten the seven hexagon-head bolts and the two fastening nuts. Affix rear wall lining.

   Fig 10: Closing Maintenance Cover (Boxster S)

   Courtesy of PORSCHE OF NORTH AMERICA, INC.
9. Installing passenger's seat

   Lift the passenger's seat into the vehicle. Connect electrical connections. Tighten the four fastening screws to 65 Nm (48 ftlb.).

   Fig 11: Lifting Passenger's Seat Into Vehicle (Boxster S)

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