From: Jay Gary Wellwood [wellwood@cswnet.com]
Sent: Friday, April 26, 2002 1:29 PM
To: 928
Subject: [928] Intake removal/installation tips....

Hey Gang-

THought I'd share a couple of possible helpful tips for the Intake dive.

When you remove the Intake, after the fuel rails are removed & the
throttle cable is popped off the Throttle Linkage, I set my Intake up on a
couple of rolls of duct tape, one on each side between the Intake Runner
and the Heads.  The allows me to remove the vacuum line underneath that
goes to the air pump discharge valve as well as the electrical connector
for the Idle/WOT switch.

When you get here, about all that is left is to get that #%^()* Idle
Stabilizer electrical connector off (hopefully in one piece!).  Since my
hands won't fit in there very easily, I opted to separate the Throttle
Body from the Intake by removing the 4 bolts (2 each side).  These bolts
are torqued to ~20 ft-lbs. and maybe a bit stubborn, but they will come
out.  Once this is done, you can remove the Intake from the engine while
the Throttle Body sits in the 'valley'.  Now you can gain easy access to
the Idle Stabilizer electrical plug!

When I installed the Intake - with the Throttle Body attached to it, the
same &##@&) electrical connector is abit of a challenge.  WHat I finally
found to work failry easily was to use a mechanical finger tool (~12" with
a flexible shaft).  Grip the electrical connector at the base where the
larger rubber boot begins, paying close attention to the orientation of
the connector.  Then laying literally on the engine and looking under, you
should be able to locate the Idle Stabilzer and using the Mechanical Tool,
shove the connector on fairly quickly (and easily).

Just my experiences...hope it helps someone.


Jay
(Seasoned Veteran of the Intake removal/installation process)