Removing intake distributor - Boxster S

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

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Removal overview: 

Fig 2: Removing Intake Distributor (Manifold) Components (Boxster S)

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1. Removing passenger's seat

   Remove the passenger's seat for better accessibility. Unscrew the four fastening screws for this purpose. Disconnect the electrical connections under the seat and take the seat out of the vehicle.

   Fig 3: Removing Passenger's Seat (Boxster S)

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2. Opening maintenance cover

   Remove rear wall lining. Then remove the maintenance cover. Unscrew the seven hexagon-head bolts and the two fastening nuts for this purpose. Take the maintenance cover out of the vehicle.

   Fig 4: Removing Maintenance Cover (Boxster S)

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3. Removing throttle body (See Removing throttle body - Boxster S  )

   Undo the four hose clamps on the throttle body. Push the two rubber sleeves outwards as far as they will go. Unscrew the fastening nuts. Remove crankcase vent. Remove centre part of intake distributor with throttle body.

   Fig 5: Locating Four Hose Clamps On The Throttle Body (Boxster S)

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4. Removing tuning pipe

   Undo the four hose clamps. Pull off the vacuum hose on the left rubber sleeve. Push the two rubber sleeves outwards as far as they will go. Take out the tuning pipe and pull the vacuum hose off the control box.

   Fig 6: Undoing Hose Clamps & Removing Tuning Pipe (Boxster S)

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5. Removing secondary air pump (USA vehicles only)

   Undo 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 to the rear. Undo the three fastening screws on the secondary air pump. Disconnect electrical connection and remove pump from vehicle.

   Fig 7: Removing Secondary Air Pump From Vehicle (Boxster S)

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6. Undoing fuel return line

   Place a clean cloth under the screwed connection and collect emerging fuel. Undo the screwed connection on the pressure regulator. An open-ended wrench must be used to counter it in order to avoid damage.

   Fig 8: Undoing Fuel Return Line (Boxster S)

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7. Undoing fuel line

   Place a clean cloth under the screwed connection. Undo the screwed connection of the fuel line. Counter with an open-ended wrench to avoid damage. Pull out the temperature switch for the engine compartment blower and set aside.

   Fig 9: Undoing Fuel Line At Pressure Regulator (Boxster S)

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8. Undoing vacuum lines

   Disconnect the vacuum lines to the brake booster. To do this, unscrew the two screws on the intake manifold. Unscrew the fastening screw of the bleeder valve for the carbon canister on the left intake manifold. See Fig 10 . Disconnect electric plug. Remove the crankcase vent on cylinder bank 1-3. Unclip the switch-over valve for the tuning pipe and set aside.

   Fig 10: Disconnecting Vacuum Lines To Brake Booster On Left Intake Manifold (Boxster S)

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9. Unscrewing fastening screws

   Open the omega clips on the fuel ring pipe and disengage the wiring harnesses. Unscrew the two fastening screws on the fuel ring pipe respectively. Unscrew the six fastening screws on the intake system on all sides. Raise the intake distributor pipes gently and immediately seal the intake channels in the cylinder head with a clean, lint-free cloth so that no dirt can enter. Lift the intake distributor upwards out of the engine compartment.

   Fig 11: Lift The Intake Distributor (Manifold) Upwards Out Of The Engine Compartment (Boxster S)

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