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A couple of notes on this. First, do not treat this as a 2.5 hour job, give yourself lots of time and do more of a mid life overhaul. Getting stuck and waiting on parts gave me time to clean my intake valves which were filthy. Lots of different methods on how to do this, but take the time. Also, the brake booster vacuum hose can be perfectly replaced with a Whirlpool Series 285664 drain hose for $17, cut to length and plug the Cayenne ends in to both ends. I also replaced all the plastic and rubber vacuum hoses. 6 ft of 3/8" high temp silicon hose was enough to do everything. I broke the plastic tee connector for the 1/4" vacuum hose, this is the same tee size as drip irrigation hose from home depot (under $2 for 10). I would also consider replacing the coolant tee which goes to the alternator at this time. Removing the alternator and coolant hoses added maybe 40 minutes of extra work, but would have reduced my overall time by hours and reduced all my yelling and frustration. I think many people trying to get the last triple square bolt off the drivers side are actually looking at the triple square on the top fuel rail which is partially hidden behind the intake. If you have the coolant hoses out of the way, it is so simple to see and remove all 3 triple squares. Not an easy job, but I am happy everything is nice and new now.
I attempted to upload some photos, but the site would not allow it. There is way way more room, and you can see everything easily. So, it is certainly more work, but I think in the end it will be less time, and hopefully remove some of the massive hangups people have been hitting. I am going to attempt to replace the coolant tee, since I removed all the lines anyway.
I made progress today, but it meant a lot more work. I drained the coolant and removed the alternator. I also removed most of the high pressure fuel pump lines, but that didnt seem to be necessary. With the alternator and coolant lines out of the way, I was pretty quickly able to put the top side of the curved fuel line into the seat of the top rail. Then like the write up, I had enough room to reach under it and get the fuel rail back through the intake manifold. I did have to pitch the manifold up toward the driver side to get the right angle, but everything went back together with that little bit more room to operate.
I am a pretty solid mechanic, and I have done lots of engine overhauls and timing belts, but this job pushed me to my breaking point. I was able to cook up the right combination of tools to get the driver's side rear triple square out, and removed the intake, and replaced all the seals. But for the life of me, I cannot get the intake to go back in place and line up the fuel rail. I attempted this for 7 hours before just giving up. First off, let me say, that the decision to put the fuel rail though the intake was completely unnecessary and maniacal. They could have just added a couple extra/separate bolts on the bottom of the intake and this job would have been 100 times easier. There seems to be no way to get the fuel rail nipple to seat back into the pump, and get it back into the holes for the intake. It will only side into my intake holes just perfectly, and there is no way to line it up like that once its attached to the pump. I tried this countless times. I also cannot get the fuel line to go down the 1/2" to slip inside the pump sleeve if the fuel rail is inside the intake. So I feel like I only have a couple options. First would be to remove the pump, and try to install that separately, which seems like more of a pain. Or make a flexible high pressure fuel line between the pump and the fuel rail. That would make this job so much more simple. I am completely out of ideas, and for now, the Cayenne is just sitting in my garage waiting for completion. I will take any advice I can get. I can easily get the intake and fuel rail back in place with the fuel line sitting directly next to the pump port, but no way to get it inside.