Ahsai

Yeah, that bolt is a PITA for me as well. Both the AOS and a wire bundle are right on top of it, blocking any tools.

spud72

Thanks very much for the replies guys. I haven't worked on it the last couple days but will drop it next chance I can. I got the other 5 bolts out easy enough and looking forward to yarding that intake out.

spud72

So started on this again today. (I only work on it a couple hours a weekend so it's a slow project!)

I dropped the motor off the back mounts and certainly has given me some more room - thanks guys.

These to hoses are being a royal PITA today and stopping me from getting a socket or a stubby wrech on that bolt.


I presume these are fuel lines. Do you guys pull these off to get at them or go about it another way? If I do move them do the hoses just come right off the steel lines? Should I be doing something else? It's a little frustrating because I am sooo close

e: Just looked closer at your photo Ashai - is there a bolt in that hole to the left of your red square? I'm just kind of feeling around in the back and that might be what I am feeling. Man, it's even tougher than I thought if so!

Ahsai

Hang in there. It takes a lot of patience. That was not my picture but I have the same holes. That hole that's left of the difficult intake manifold bolt is for a nylon cable tie, no bolt goes through that hole.

You may have to do everything by feel. I did.

spud72

I hear ya, everything for that sucker has been by feel until now.

I actually think I'm going to try getting at it from the right hand side and remove that top rad hose that is in your photo. I have the alternator out so it's very open on that side. I already emptied out the coolant top-side of the motor and would give me an "almost" straight shot at the bolt other than the top of the AOS being in the way but at least it's visible on that side which is a plus!

But now I am hung up by a friggen PITA hose clamp! Even completely opened it's still too big to slide up. Grrrrrrr!

Ahsai

Have you tried pushing the AOS straight up for an inch or so? Then you should have a straight shot of that bolt from the top (by feel).

spud72

No, not yet but thanks for the tip. I have removed the 2 mounting bolts but since I've never done it before I wasn't sure how much I can get away with moving/jostling things.

I think I'm going to try taking out that hose tomorrow and work that angle. It's really a fairly straight shot at it from there and I think will make it easier to start the bolt for the re-install.

Did you guys re-loctite those intake bolts or just torque up as-is?

Ahsai

I just reused the old bolts and torqed them to spec. No loctite used.

DBJoe996

When you manage to get the last bolt a little bit loose, you can pivot the manifold a little bit to the left and get the rear plenum unattached. Then you can pivot the intake manifold to the right and gain a little better access to the rear bolt. Make sure to have a magnetic socket or a magnet in there to catch that bolt. Since you are working blind, you don't know when it finally comes out and it is easy to drop. Took me two days to find that bolt! Also remember that there are intake manifold gaskets (oval O-rings), so when you finally get it out make sure all three are still on the manifold. Otherwise, they dropped into one of the intakes and you will need to fish it out.

Slakker

You are almost there. No reason you shouldn't be able to get the bolt from above with a 1/4 ratchet, extension and U-joint.

It only took me an hour to find the bolt I dropped. Went up through the wheel well IIRC. Total pain but not tragic.

Gretch

This is a fascinating thread......... great reading.

spud72

Got you, you rat bastard


The prize is now easily in sight


I had Mrs. Spud72 holding my flexible magnet in off the socket as I pulled it off in case it fell, just as you guys mentioned.

After I pulled the intake she looked at me, mouth slightly agape at the underhood condition of our Porsche. She said "Don't you die until you get this fixed and out of the garage!"

Slakker

I like Mrs Spud.

Congrats!! Changing your AOS is almost a DIY "right of passage" on these. You have a few hurdles left but just stay after it. You are almost halfway there!

spud72

She's a sweetheart, really.

Hey it looks like there are pinch-style clamps on a couple of those lines off the AOS. Do you guys just cut those off and replace with standard clamps? I haven't run across those yet until now and would rather avoid cursing and swearing for several hours on a couple of stupid clamps.

Ahsai

I usually don't reuse those spring style clamps, especially if they are so difficult to access if they cause a leak. They tend to loose their strength with age. I would replace those with new identical ones or just the worm type.