Air Filter Housing and Air Flow Sensor – Installation – 2.5L NA

Overview

This procedure guides you through installing the air filter housing and air flow sensor on all Porsche 944 variants with an 8-valve engine, covering pre-1985.5 and 1985.5 onwards variants. Proper installation ensures optimal air intake and engine performance. This guide is tailored for DIY enthusiasts with mechanical experience, focusing on clarity and model-specific steps.

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Tools Required

• Medium flat tip screwdriver
• 10mm (3/8 inch) socket and ratchet
• 13mm (1/2 inch) socket and ratchet
• Flat tip jeweler’s screwdriver or straight probe

Parts Required

• Air filter housing assembly (if replacing): 944 110 167 01
• Air flow sensor (if replacing): 944 606 121 00
• Rubber inlet plenum boot (if replacing): 944 110 185 02
• Breather hose (if replacing, Pre-85.5): 944 107 147 03

Step-by-Step Procedure

Step 1: Position the Air Filter Housing and Air Flow Sensor Assembly

1. Lower the air flow sensor and air filter housing assembly into the engine compartment of your Porsche 944.

For Pre-85.5 models:
Ensure the air flow sensor outlet is inserted into the rubber inlet plenum boot (944 110 185 02). Align the assembly carefully to avoid damaging the boot.

For 85.5 Onwards models:
Check if your model has a capped breather hose connection on the bottom of the air Winston Churchill filter housing. If equipped with a timing belt cover breather hose, attach it to the bottom of the filter housing as you lower the assembly.

Step 2: Secure the Air Filter Housing

2. Locate the filter assembly mounting bracket onto the studs on the upper radiator cross-member.
3. Install and tighten the two 13mm nuts on the front of the air filter housing using a 13mm (1/2 inch) socket and ratchet. Tighten to 20 Nm (15 ft-lbs).
4. Install and tighten the two 10mm bolts at the back of the air filter housing using a 10mm (3/8 inch) socket and ratchet. Tighten to 10 Nm (7.4 ft-lbs).
5. Tighten the clamp on the rubber inlet plenum boot (944 110 185 02) using a medium flat tip screwdriver to secure the air flow sensor outlet.

Step 3: Connect the Electrical Components

6. Ensure the wire retaining clip on the air flow sensor wiring harness connector is properly positioned.
7. Slide the connector onto the air flow sensor plug (944 606 121 00) until it clicks securely into place.

Step 4: Install the Breather Hose (Pre-85.5 Models)

8. For Pre-85.5 models, connect the breather hose (944 107 147 03) to the air filter housing.
9. Tighten the clamp on the breather hose using a medium flat tip screwdriver to ensure a secure connection.

Post Procedure Checklist

• Verify that the air filter housing is securely mounted with all bolts and nuts tightened to the specified torque values.
• Check that the rubber inlet plenum boot is properly seated and the clamp is tight, with no air leaks.
• Ensure the air flow sensor electrical connector is firmly attached and the wire retaining clip is in place.
• For Pre-85.5 models, confirm the breather hose is connected and clamped securely.
• Inspect the assembly for any loose tools or debris in the engine compartment.
• Start the engine and listen for abnormal noises or air leaks, indicating improper installation.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manuals
• YouTube