RngTrtl

Dear All, 1985 928 auto 32v 5.0

I have gone over the board throughly (I think) and I have not been able to find any information/tips on removing the intake manifold/s so that I can replace the gaskets and vacuum lines that are under there. I have seen the info for the 78-84 and for the 87+, but not any for the 85-86. I do have the manuals on cd so that helps, but I also know that there is alot of info left out of those. If anyone would please offer me any advice, I would greatly appreciate it. Thanks

JEC_31

The most important tool is time, as that intake has more parts than the average Kia.

I rememer a long afternoon of nothing but cleaning all 20 hose clamps...

Dave Howerdel

RngTrtl,
First off welcome to Rlist.
The intake removal is fairly easy as you take note of hose routing etc. Simplifying it:
1)Remove intake sides(rubber/hoseclamped connectors)
2)Disconnect fuel hoses, rail/injectors 10mm bolts. and remove.
3)Unbolt intake and remove taking care not to drop any debris into the head. 13mm bolts
4) now your free to check/replace hoses, gaskets etc.
Oh and while your in there, might as well replace the ISV as well.

Jim bailey - 928 International

The 85-86 intake is pretty easy since it comes apart where the 11 rubbber boots and 22 hose clamps hold it together. The intake runners are joined so two intakes come off together but this modular design makes it much easier to access than the later 87 > intake where all eight runners are a single casting. Just be very careful not to drop anything into the intake ports and do not be surprised or alarmed to find residual blow by oil coating the inside of the intake.

Shane

The injector rails and injectors need to be pulled, your spark plug wires will have to be removed from the fuel rails to allow removal of the rails. Mark where all of the vacuum lines go so as not to get them mixed up when you put it all back together. Once you have the fuel stuff out of the way it will be easy to identify what is next and how it comes apart. 10 bolts for the intake and hose clamps for most of the rest. Pretty easy once you get into it, but it looks like a maze when it is altogether and a little intimidating. If you run into some thing you can find a place for when you do reassembly, post a pic of it and we can help guide you to where it goes. HTH

Big Dave

Welcome to the forum!

When I did my rebuild, I kept a copy of the vacuum hose diagram since I knew it was a common question. You can ignore the valve circled in green....that's the one I removed since I deleted my air pump.

Hope this helps. As the others have said, removing the intake is fairly easy once you start turning the wrenches.

SteveG

1. Someone already mentioned the ISV?
2. Have injectors cleaned?
3. Powder coat intake?
4. Replace "U" shaped fuel line on the firewall. I think it there are two back there, one connects using only clamps, no threading and on mine it was a fire waiting to happen.
5. The covers use a special rubber backed washer. You can get them or an identical replacement from Fastenal for 1/10th what Porsche will charge you.

ssimchock

Do you have a part number or a place to purchase the Fastenal washer?

RngTrtl

Man, I can hardly believe the greatness that y'all (yes I live in mississippi! ) have given me. Thanks alot for all the help. I have lusted after the 928 since I was a wee tott of a child and I lucked on to one on ebay during thanksgiving for 2k. im doing this ona college budget so the cheap hints are great! Im gonna start turning the wrenches on Mon. (We get General Robert E. Lee b-day off from school). Thanks again, im glad to hear that there are no "big deals" in this intake. Y'all take care.

p.s.: i am assuming that now would be a good time to also check the preload on the flexplate to prevent TBF huh?

~RngTrtl

jeff jackson

Rng Trtl... Monday (here in Lincolnland...is "Martin Luther King day") ...hence no school. Funny coincidence...no ???

Shane

Not really needed on the 86 as on the higher hoss power S4's. The only time I got any really noticable movement out of mine was after I had run with the supercharger.

RngTrtl

The Robert E. Lee b-day thing is kinda a joke, offically it is MLK day, but seeing is how we learn how to whistle Dixie before we learn twinkle twinkle lil' star, we call it The General's Day

RngTrtl

Dear All helpers,

Thanks for all the help and insight for the removal on the intake and associated stuff with it...Note to the future removers. Rather than trying to remove the fuel rails with the injetors attached to them from the intake manifolds, I suggest undoing the clips on the injectors that secure them to the rail and leaving them on the intake when lifting the fuel rail. Then undo the injector wires then remove manifolds, then remove injectors from the intake manifolds. This is what worked for me. I found that on the 1st try that i almost broke a fuel injector trying to get the rail and injectors off as a complete assembly. The rail actually popped passed the upper clip on the fuel injector leaving the injector on the intake anyway. Thank goodness that it didn't break the injector as this happened. After I removed all the clips, the rail popped off with no problems. I hope this helps.

figgen

for some good info on the 85-86 MY check out:

http://groups.msn.com/thediygang

RngTrtl

Another few questions to all...I have gotten all the intakes sandblasted and painted and clear-coated. Tomorrow I plan to start reconstruction.
Question #1, Do I need any kind of sealant for the two large O-rings that go in the air guide and MAF? I have 1 rather large one that fits into the airguide, and 1 that fits around the MAF. Both just seem to pop in and/or around, but i would think that there would need to be some kind of sealant that is needed (like some gasket seal or something).
Question #2, I have used a tad of Vaseline (Petroleum Jelly) around the fuel injector seals to get them to seat right on other projects and have heard that this is good practice. Can I use just a tad of axle greese the same way for the injectors of this 928? The only reason I ask is that I do not have any Vaseline laying around, but do have axle greese. Buying some would be no problem, but I am curious because they have the same consistancy.
Question #3, Should I put the fuel injectors in the manifolds before I mount them or after, and then mount the fuel rail on top of them? I would think that it would be easier to mount them into the intake 1st then mount the intakes, and then the fuel rail, but then I run the risk of fouling up an injector huh?

Thanks to all for all the help. Y'all Rock!!