Starter motor replaced then how to "painlessly" put the plenum back together

Was helping a friend with his starter motor replacement for his 987.1 BxS (2008). While the starter replacement was relatively painless (for 2 people), we had a hard time putting the plenum back in place. We tried different ways / methods for 2 hours and was getting late, hence, we "gave up" (and reconvene soon). A few youtubers says "take your time" and/or "do it in reverse order" but no specifics or hints. While my friend and I are NOT pro mechanics, we have done various work with our Boxsters and others cars so we are not complete novice, yet having a hard time putting the plenum back in place. We have very little wiggle room and not as easy as "take your time and just put it in". If you have experience and/or some insights re: how to put the plenum back in place, it would be greatly appreciated as this is taking longer than the starter replacement Or if you have WM "24 46 20 Removing and installing intake-air distributor" that may help as well - I have the service manual but does not seem to have this particular instruction. Thanks

I too had a terrible time with this when I replaced my starter. I did not find a "good" solution - I just wrestled it for a couple of hours until I finally got it. It did take a fair amount of strength to deform the rubber just enough to get it to go in. Sorry I can't give you a better answer! Hopefully someone else on the board has good method.

I hear you as we are going through the same experience. I was ready to go over after work today but my friend was able to figure it out (plus it was getting dark even with a lit garage). A few pointers: 1. get the bottom (below the throttle body) aligned / inserted first (some force and "rolling up / align" the rubber) 2. ensure you align / insert the "left, bottom arc" of the plenum into the rubber hose first, then wiggle to get the top part inserted - once you have the left side in, just enough room to insert the right side I guess these is no easy solution and this is like a marriage...sounds good and easy in theory but when you actually go through it........(I will stop here )

Make sure both rubber collars are pushed as far apart as possible. Assure that the clamps can’t cause issues - I often don’t install them until the parts are fitted. And biggest tip - use silicon spray on all the parts to ease the assembly.

Thanks for the reply and insights. I also suggested, as I always do, the silicone spray but he ran out...a Murphy s law

I like the idea of the silicone spray, I bet that helps a lot. Thanks!

Lube always helps (pun intended ). Joking aside, Since I use Super Lube for my pool equipments / plumbing, I also use it for "rubbery" stuff for our cars (especially older ones to prevent dry / cracking rubber seals / gaskets). One of the first things i did when I got my 987 back in April is applying light coating to all rubber seals (since it is 18 years old).

Silicone spray (or white lithium grease) is nice, but sometimes can be more of a hassle than it's worth. Try glass cleaner. Any glass cleaner. Windex , SprayWay, Wurth, etc. It provides the lubricity needed in the moment and then dries residue free. Works especially well on boost piping where you want the silicone/rubber coupler to tack to the pipe after install. As for the intake tubes, sorry, spray the couplers then use patience and a methodical approach. They aren't the greatest to install.

I'm reluctant to use any silicone lubricant on anything with an internal engine connection. I've used a light film of Simple Green and also 99% IP alcohol. The alcohol is nice because it evaporates very quickly. Congrats on your friend's persistence.

I’ve been using silicone spray as an assist for these sorts of things for over 20 years with no issues This is the brand that I use but others are similar. Despite the fact that it says heavy duty, the stuff only seems to last about 15 minutes and then it disappears.

A great insight. He tried in the morning and was able to do it in 15 mins One of those...

I pushed the rubber hoses as far as they would go onto the plenum rather than outward onto the manifolds. They will go past the end of the plenum so it's easy out easy in. At least on mine.

Also, piggybacking on this thread (not jacking it!) the DIY in the Porsche project book and some of the Youtubes for the starter removal do not reference the socket needed to remove the bolts in the starter. It's an E14 which is an external torx bolt. I guess some of the cars have regular hex head bolts. Once I got that socket it was easy to remove.