9 captured repliesDiscussion pagination complete · Source accounts, not a confirmed diagnosis
THIS DISCUSSION / SOURCE-DERIVED OVERVIEW
Discussion summary
YOUR RESEARCHTrouble reinstalling intake plenum
Leading reported evidence
Tighten cross tubes are causing the mis-alignment
Performed · outcome unconfirmed
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
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Discussions that performed work without a confirmed outcome
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Performed · outcome unconfirmed · Original poster
I think the tightened cross tubes are causing the mis-alignment.
Leading evidence: 'Tighten cross tubes are causing the mis-alignment' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Replace leaking oil cooler o-rings' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
Source reports, not a diagnosis or a success probability. Counts refer to discussions and can overlap.
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1
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Suggestion · Original poster
It went on perfectly with the engine out, but I had to remove it again to replace leaking oil cooler o-rings.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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Suggestion
Can you use long set screws or longer bolts with the heads cut off as guide pins to align the intakes?
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
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0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
Can you use long set screws or longer bolts with the heads cut off as guide pins to align the intakes?
Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
9 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
Rennlist: 1 discussions
0 evidence records excluded for query context · 0 excluded by outcome qualification · 0 adjusted by outcome qualification.
0 acknowledgements have no verified action link; they do not establish a repair result.
Generation: 20261026T122219Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
Does anyone have a method to reinstall the right side intake plenum on a 996.2? It went on perfectly with the engine out, but I had to remove it again to replace leaking oil cooler o-rings. I know, shoulda done that with engine out, but they looked fine. Lesson learned. Anyway, the job is nearly done, and now I'm on my third day of trying to line up the plenum with the intake manifold. I can only get the bolt at the back of the block nearest cylinder 4 to start threading. With that bolt partially in to allow some rocking, the others bolts still don't line up. I have tried inserting a small hex wrench into the other holes and each hole is obstructed, even with the first bolt in. I push, I pull, I go left and right, with no luck. This is a literal back breaker, and I have the engine lowered 3" and the car on jack stands. Really aggravates the old lumbars to wrestle the plenum back and forth for an hour at a time. Any help would be appreciated. I don't want to open the band clamps on the cross tubes, because they took forever to line up without crimping the rubber sections.
The intake at this point is already resting on the manifold, and is only out of alignment by half the width of the hole or less. I think the tightened cross tubes are causing the mis-alignment. I just hate to think about opening them again after all the trouble they gave me the first time. Maybe I'll try to loosen them without opening a gap between the tubes and the rubber sleeves and the manifold ducts. That way I may get that last little bit of wiggle room I need to start each bolt. Thanks, you're helping me by being a sounding board. Two heads are way better than one!
Okay. I loosened the straps closest to the plenum. That gave it a little bit of wiggle room. After an hour and a half of work I've managed to get 5 of 6 in. The last one is at the front of the engine, which of course I can't see, so I'm going by feel. I'm done for the night. I think it's more about screw angle than movement of the housing. Try again tomorrow.
Yes I too got a chance to experience this scenario... leaky oil cooler rings that were too small after installing them during my engine rebuild. It took me several hours but the only way was to loosen the clamps on left and right intakes to get enough wiggle room. I also removed the screws holding the fuel rail on the right hand bank. Do able but not fun. Glad that you were able to get yours back together.
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