Porsche Cayman S IPD Intake Plenum Installation Instructions

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1 Porsche Cayman S IPD Intake Plenum Installation Instructions Text and images Copyright 2007 Sam Barone All rights reserved. No commercial use. No warranty expressed or implied. junkmail-cayman@shread.net Revision: Tools needed: Large flat head screwdriver (or equiv) to pry-up the foam rubber backed carpet engine covering. Torx T-30 driver to remove the engine cover bolts. 7 mm socket for all the hose clamps (note: most of the clamps have hex heads with cross groves for a Philips driver, but the ones on the MAF senor only have a slotted grove use the socket instead of drivers ) 8 mm socket for the (E10) bolts that secure the throttle body to the plenum, for the oil filler tube bracket, and the stock plenum hold-down nut. Pliers or channel lock pliers for the steel squeeze-type clamp on the plenum vacuum line. Overview: The factory intake is comprised (in order) of the air box / filter assembly, a Mass Air Flow sensor, a ribbed hose, egas throttle body, and then the plastic plenum. The plenum has a vacuum operated internal flapper that when closed separates the airflow into independent channels for each set of cylinders; when open allows the air to mix between both banks inside the plenum. In its open state, the plenum is far from what might be called free flowing. Essentially, the installation process involves removing and discarding both the factory plenum and the ribbed hose the connects the MAF sensor to the throttle body, then mounting the throttle body directly to the IPD plenum, and connecting the IPD silicone hose from the MAF sensor to the throttle body.

2 Detailed steps: The engine is under here. 1. Remove the carpeted foam rubber-backed covering. The covering is secured by tabs that extend into slots in the body and is fairly flexible because of the foam rubber backing. Remove the luggage net. From behind the cover, start at the edge closest to the front of the car, and pry the edge of the cover back towards the rear. A screwdriver wrapped in something to protect the plastic finish or strong fingers work well here. Once one corner is pried up enough to free one of the tabs, it ll then be clear to how remove the whole cover. The tabs on the edge closest to the front of the car are smaller than the ones in the rear, so start there.

3 2. Remove the aluminum engine cover. Remove the 5 bolts securing the cover using a T- 30 driver.

4 Refer to the picture above to orientate yourself with the location of the relevant factory engine components. The plenum is the curved T shaped plastic assembly in the foreground in the image above. For reference, the plenum, removed, is pictured top-down above. 3. Remove the crank case breather hose connections from both sides of the plenum and from the opposite end where it attaches to the oil separator. There are raised grooves at 12 o clock and 6 o clock on these connectors. To release them, squeeze the grooved sections between the thumb and index fingers and pull the connector free. These can be difficult to release; resist the temptation to use tools on these connectors. After disconnecting all three connections, remove and set aside the assembly. A close up of the removed connector is shown below.

5 4. Loosen the four hose clamps (two on each side) around the rubber boots that are between the plenum and the intake manifolds. Loosen the clamps so that they are complete slack. Slide the rubber boots as far to the outside (away from the plenum) as they can go. This will make it easier to remove the plenum from between the boots.

6 5. Loosen the hose clamp on the throttle body (the ribbed hose that connects the MAF sensor to the throttle body).

7 6. Remove the plenum hold-down nut.

8 7. Separate the rubber boots from the plenum and carefully lift it up and away. There are two vacuum connections on the under side of the plenum. Don t move the plenum too far away. 8. Remove the ribbed hose from the throttle body. This will allow easy access to the bottom of the plenum 9. Remove the vacuum lines from the plenum. The bigger of the two is held on by a squeeze-type clamp that will require pliers / vice-grips to squeeze in order to remove the hose. The second smaller line goes to the vacuum motor that operates the flapper valve inside the plenum. This line is not held on with a clamp and it pulls straight off, however, it is very hard to remove. The line will stretch quite a way, but it should pull off. (Don t be tempted to cut the hose it will be impossible to get the small severed end of the hose out of the recessed connection if the factory plenum ever needs to be reinstalled,).

9 10. The IPD plenum comes with two plugs: An aluminum plug, and a small black plastic plug. Use the small black plastic plug to plug the end of the vacuum line that was removed from the flapper valve vacuum motor. Tuck the vacuum line away (it is not used by the IPD plenum). 11. Remove the clamp on the ribbed rubber hose on the MAF sensor. Remove the ribbed hose (it is not used by the IPD plenum). 12. Remove the throttle body from the plenum by removing the four E10 (8 mm) bolts. The factory plenum should now be completely disconnected. Remove the plenum.

10 13. Remove the oil filler tube bracket bolt and the bracket that surrounds the tube. Unscrew the plenum hold-down bolt / rubber grommet the bolt should unscrew with the grommet together. These steps are needed to provide clearance for the IPD plenum. Note: with the removal of the oil filler tube bracket, the final install will result in the IPD plenum resting directly on the tube pressing it between the throttle body servo casing and clutch housing underneath (because of the shape / length of the silicone hose). It is probably a good idea to wrap the tube with something non-abrasive (like thin rubber) at the point where the bracket used to be, in order to prevent the plastic oil filler tube from becoming abraded over time. 14. Connect the thick vacuum hose that was removed from the old plenum to the nipple on the underside of the IPD plenum. Use pliers or channel locks on the metal clamp to position the tube in place. 15. Position the IPD plenum between the two rubber boots between the intake manifolds. Adjust and tighten the clamps on the plenum-side of the boots. Leave the manifoldside clamps loose so that the plenum can be easily repositioned during the remaining steps. Note: be absolutely sure that the boots are positioned such that they completely seal the side openings of the plenum.

11 16. Install the throttle body on the IPD plenum using the E10 bolts and an 8 mm socket. Mount the throttle body so that the solenoid (the black box hanging off the side) is on the left side when viewed from the rear of the car. 17. Move the left shifter cable so that it is on the left side of the throttle body (leave the right cable where it is). Refer to the image above when positioning the throttle body and the left shifter cable. Note: The image shows the silicone hose installed though it should not yet be installed at this point in the process. 18. Carefully bend the body tab upwards slightly so that it will not come in contact with the IPD silicone hose once installed (see the image above). Use pliers wrapped in a soft cloth to bend the tab. 19. Position the large end of the IPD silicone hose onto the MAF. Secure the MAF sensor end of the hose with the factory clamp. Tip: Position the hose, then loosen the factory clamp all the way so that it separates (opens up), then slide the open ends around the hose, rejoin the ends, and tighten the clamp.

12 20. Position the open end of the silicone hose on to the throttle body. Due to the shape of the hose, this will require a good deal of elbow grease to position the plenum in such a way that the end of the hose fits completely and evenly flush with the throttle body. Secure the hose with the factory clamp. See the tip in the previous step for putting the clamp on after positioning the hose. 21. Firmly tighten the intake manifold-side clamps around the rubber boots at the plenum. It should be firmly secured in place at this point.

13 22. Firmly insert the aluminum plug supplied with the IPD plenum into the left end of the plastic crank case breather hose assembly. It is held in place by friction the clamp will not snap into place.

14 23. Place the breather hose assembly in place on top of the plenum such that the u shaped part of the hose assembly is resting upside down over the plenum. The plugged end should be on the left side of the plenum resting freely. 24. Carefully snap the right side breather hose assembly connector onto the oil separator. Be sure the connector is aligned so that the assembly can be pushed straight on to the separator. 25. The most difficult step is saved for last. Push the remaining open end of the breather assembly onto the nipple on the left side of the IPD plenum. It is clear that the nipple is not in the right place to easily use the factory breather tube assembly easily. It may require a great deal of force to bend the tube into position such that it clicks into place on the plenum. Note: limited experience shows that it is possible to position the breather assembly in the required position without damaging it, however, using a heat gun on the breather tube assembly may make positioning the assembly in the required position easier. 26. Recheck the positioning of all the hoses, boots, and verify that all of the hose clamps are tight.

15 Install complete. Note: install may not look this good without Meteor Grey and Terracotta 27. Reinstall the aluminum engine cover and secure with the five T-30 bolts. 28. Reinstall the rubber-backed carpet piece by inserting the rear tabs into the body slots first. Then flex the cover piece until the side and finally the front tabs are all in place. While doing this, be sure that the luggage net hold-down d-rings are sticking up above the cover. 29. Reattach the luggage net.

16 -- End. 30. Wash hands. 31. Get in and drive! Put various loads on the engine for as many miles as is practical. It is not necessary to reset the DME for it to learn that it will now see more air (all other things being equal) and that it can use more fuel Text and images Copyright 2007 Sam Barone All rights reserved. No commercial use. No warranty expressed or implied.

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