Installing Intake-Air Distributor

→ Ventilate the work area well.

→ Never ingest or inhale.

→ Read specific information on the Hazard Sheet.

→ Wear personal protective gear.

→ Do not smoke, eat or drink in the work area.

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapours.

→ Attach warning sign in a clearly visible position.

→ Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.

→ Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.

→ Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.

→ Only install clean parts. Do not take spare parts out of the packaging until just before installation.

→ Never use compressed air when the system is open. Do not move the vehicle.

→ Perform leak test.

Information 

• Do not bend high-pressure lines. Always remove the high-pressure distributor pipe and other fuel-supply components in the high-pressure area completely. Check that the connection points are not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks following fitting. 

Information 

• The ignition must be switched off when working on the fuel system. 
• Absorb any escaping fuel using a suitable binding material or a cloth. 
• Cloths which have absorbed fuel must be disposed of according to the applicable national laws. 
• The fuel system must be depressurised before starting work on it. 
• Only work on the fuel system in well-ventilated rooms. 
• Any seals which have been removed must always be replaced. 

Information 

• The lower fuel distribution pipe also secures the intake-air distributor. 
• Always open the fuel high-pressure system when removing the intake-air distributor. 
• The intake-air distributor sits under the fuel distribution pipe for cylinders 2, 4 and 6 

1. Replace intake-air distributor gaskets.
2. Replace the gaskets between the fuel injectors and fuel distributor pipe (for cylinders 2, 4 and 6) and coat them with clean engine oil.
3. Only complete the following step if screws are defective:  To replace the integrated screws for the intake-air distributor, carefully drill out the three openings using a 13-mm drill bit. When doing so, make sure the drill holes do not exceed a max. depth of 15 mm.
   Fig 1: Removing Intake-Air Distributor Mounting Screws

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4. Insert the lower fuel distributor pipe (for cylinders 2, 4 and 6) into the removed intake-air distributor.
   Fig 2: Identifying Pre-Fitting Lower Fuel Distributor Pipe

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5. Fit intake-air distributor complete with the lower fuel distributor pipe. To do this, first guide it in on the intake side -1-  , then tilt it to the cylinder head on the exhaust side. -2- 
   Fig 3: Installing Intake-Air Distributor

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Screw in screws/side screws on intake-air distributor. Use a thin Torx socket (e.g. Klann KL- 4041-240) to tighten the screws hand-tight.
   Fig 4: Identifying Intake-Air Distributor Mounting Screws

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   Fig 5: Identifying Intake-Air Distributor Side Screws

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   Information 

   • The lower fuel distribution pipe also secures the intake-air distributor. 
   • Always open the fuel high-pressure system when removing the intake-air distributor. 
   • The intake-air distributor sits under the fuel distribution pipe for cylinders 2, 4 and 6 
7. Good lighting is essential when working in confined spaces!  Fit lower fuel distributor pipe (for cylinders 2, 4 and 6) together with the intake-air distributor. To do this, press the lower fuel distributor pipe correctly onto the injectors. Move fuel distributor pipe into installation position. Fit screws and tighten by hand. To do this, insert a suitable extension in between the water tube and fit the three screws using a multiple-tooth socket. .
   Fig 6: Identifying Lower Fuel Distributor Pipe Accessing Screws

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Tighten screws on the intake-air distributor and fuel distributor pipe. → Tightening torque: 30 Nm (22 ftlb.)  , then → Torque angle: 90° → Tightening torque: 8 Nm (6 ftlb.) 
9. Fit high-pressure line between the fuel distributor pipes. To do this, fit union nuts loosely. -1 and 2-  See Fig 7-21-  .
   Fig 7: Identifying High-Pressure System Threaded Connection

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   Fig 8: Identifying DFI Injection System (3.6L)

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10. Fit high-pressure pump. → Installing High-Pressure Pump  .
11. Fit water tube. To do this, insert the water tube into the latch on the intake-air distributor and slide it back towards the plenum panel -arrows-  . Fit the screw into the intake-air distributor -1-  .
    Fig 9: Inserting Water Tube Into Latch On Intake-Air Distributor

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12. Connect vacuum line to the vacuum unit of the intake-air distributor -1-  . Clip on change-over valve and fit cable plugs. -2 and 3- 
    Fig 10: Identifying Vacuum Lines

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13. Press the two coolant hoses onto the intake-air distributor and fit screw on oil dipstick. Insert dipstick. -1- 
    Fig 11: Pressing Coolant Hoses Onto Intake-Air Distributor

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
14. Fit rear screw on intake-air distributor. -1-  → Tightening torque: 20 Nm (15 ftlb.) 
    Fig 12: Identifying Intake-Air Distributor Fastening Screw

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15. Insert vacuum line into the intake-air distributor. Grease connection and seal -2-  with Kluber Syntheso Glep 1 as required. -arrow- 
    Fig 13: Inserting Vacuum Line Into Intake-Air Distributor

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
16. Fit throttle housing cable -1-  . Fit screw on intake-air distributor. -2-  → Tightening torque: 20 Nm (15 ftlb.) 
    Fig 14: Identifying Throttle Valve

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17. Fit upper screw on sheetmetal holder. -Top arrow-  → Tightening torque: 20 Nm (15 ftlb.) 
    Fig 15: Locating Exhaust Manifold Heat Protection Panel Mounting Screw

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18. Fit connections and accessories on intake-air distributor.
    Fig 16: Identifying Intake-Air Distributor Connections

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    1. 18.1. Screw on oil filler cover. -1- 
    2. 18.2. Fit eyelet. Tighten two screws. -2-  → Tightening torque: 23 Nm (17 ftlb.) 
    3. 18.3. Connect cable plug for throttle valve. -3- 
    4. 18.4. Fit tank vent line. -6- 
    5. 18.5. Fit positive crankcase ventilation line. -5- 
    6. 18.6. Connect cable plug for crankcase heater. -4-