Removing V8 Intake Plenum .. HELP
Discussion
Hey guys, I have a 97 V8 Esprit and I need your help in removing the intake plenum so I can access the spark plug wires and change them. I've only un-bolted the 14 bolts on the top of the plenum and it's now somewhat loose, but I dont know what else needs to be removed to get the plenum off. Please advise. Thxs in advance!!!
Al
Al
TBH I just kinda kept pulling at it and everything that moved I removed 
It all looks a bit scary, but in reality it isn't too bad.
Anyway from memory;
At the Front
Pull the 2 fuel lines at the front. They disappear just the plenum and have a red button either side, you squeeze the red button and then just pull. If you're not as crazy as me, you may wish to relieve the fuel pressure before doing this
The elctrical connectors either side of the front of the plenum
The MAP sensor and the throttle position sensor
The throttle cable
The 2 rubber hoses that connect the throttle body to the intakes from the turbos
There a red vacuum hose that goes to the throttle body
A blue hose behind this that is used for idle control
I think on US cars there's an EGR pipe that need removing also, someplace near the throttle body.
At the Back
There's a load of black hoses at the back that are all mostly obvious. You'd don't need to disconnect the fuel hose as the fuel rail is left behind.
Back left hand corner there is a small vac hose that goes to the fuel pressure reg.
There the electrical connector that goes to the idle control valve, but I'd leave this and remove it as you lift the plenum.
All in all it isn't too bad. Once you've got it lifting it all becomes more obvious what's left to remove. If you cant move it at the mo my feeling is you've most likely left the fuel pipes on at the front or the rubber hoses feeding the throttle body.
One word of warning, be careful when tightening the bolts back up on top. The toss bag that last did mine stripped a couple of the threads
It all looks a bit scary, but in reality it isn't too bad. Anyway from memory;
At the Front
Pull the 2 fuel lines at the front. They disappear just the plenum and have a red button either side, you squeeze the red button and then just pull. If you're not as crazy as me, you may wish to relieve the fuel pressure before doing this
The elctrical connectors either side of the front of the plenum
The MAP sensor and the throttle position sensor
The throttle cable
The 2 rubber hoses that connect the throttle body to the intakes from the turbos
There a red vacuum hose that goes to the throttle body
A blue hose behind this that is used for idle control
I think on US cars there's an EGR pipe that need removing also, someplace near the throttle body.
At the Back
There's a load of black hoses at the back that are all mostly obvious. You'd don't need to disconnect the fuel hose as the fuel rail is left behind.
Back left hand corner there is a small vac hose that goes to the fuel pressure reg.
There the electrical connector that goes to the idle control valve, but I'd leave this and remove it as you lift the plenum.
All in all it isn't too bad. Once you've got it lifting it all becomes more obvious what's left to remove. If you cant move it at the mo my feeling is you've most likely left the fuel pipes on at the front or the rubber hoses feeding the throttle body.
One word of warning, be careful when tightening the bolts back up on top. The toss bag that last did mine stripped a couple of the threads
This procedure is ED.4 in the workshop manual.
Should you need full details, ask the technical boys at the factory to fax you pages 15, 16, 17 and 18 from the manual section ED (V8 Engine)
1. Release fuel pressure. the fuel system retains pressure even when switched off:
Disconnect the fuel pump feed, start the engine and run until starved. Crank for 10 seconds more.
2. Release quickfit connectors of secondary injector pipe assy from rear of fuel rails. Prees the two red buttons on each connector to release the retaining clip.
3. Remove air intake hose clips on throttle body intake elbows, release the IAC valve hose from th RH compressor outlet duct. Remove single screw fixing each duct to cylinder head. Remove the hoses connecting the ducts to the throttle body intake elbows.
4. Release harness connectors to MAP sensor (thing with GM written on it) Release harness to throttle position sensor on right of throttle body and to the 2 secondary injectors.
5. Disconnect EGR pipe at joint near throttle body intake elbows.
6. Release throttle cable from quadrant lever and the abutment on the throttle body.
7. At front of plenum, disconnect vacuum supply to brake servo and small hose to climate and AIR systems.
8. Release vacuum hose between plenum and fuel pressure regulator valve
9. Release primary breather hose from rear end of right cam cove
10. BET YOU WISH YOU'D NEVER ASKED !!!
11. Disconnect translucent purge hose between EGR manifold and non return valve at front of engine bay and red boost sensing hose from RH side of throttle body.
12. Lift plenum to allow you to disconnect IAC connector plug, EGR valve connector plug and EGR temp. sensor.
13. Stick something in intakes to prevent debris entering the intake ducts
14. PHEW !!!!
Like I said, ask for the relevant pages or e-mail me for more detail. Hope this helps. Cheers- Toyroom
>> Edited by toyroom on Wednesday 11th May 22:45
Should you need full details, ask the technical boys at the factory to fax you pages 15, 16, 17 and 18 from the manual section ED (V8 Engine)
1. Release fuel pressure. the fuel system retains pressure even when switched off:
Disconnect the fuel pump feed, start the engine and run until starved. Crank for 10 seconds more.
2. Release quickfit connectors of secondary injector pipe assy from rear of fuel rails. Prees the two red buttons on each connector to release the retaining clip.
3. Remove air intake hose clips on throttle body intake elbows, release the IAC valve hose from th RH compressor outlet duct. Remove single screw fixing each duct to cylinder head. Remove the hoses connecting the ducts to the throttle body intake elbows.
4. Release harness connectors to MAP sensor (thing with GM written on it) Release harness to throttle position sensor on right of throttle body and to the 2 secondary injectors.
5. Disconnect EGR pipe at joint near throttle body intake elbows.
6. Release throttle cable from quadrant lever and the abutment on the throttle body.
7. At front of plenum, disconnect vacuum supply to brake servo and small hose to climate and AIR systems.
8. Release vacuum hose between plenum and fuel pressure regulator valve
9. Release primary breather hose from rear end of right cam cove
10. BET YOU WISH YOU'D NEVER ASKED !!!
11. Disconnect translucent purge hose between EGR manifold and non return valve at front of engine bay and red boost sensing hose from RH side of throttle body.
12. Lift plenum to allow you to disconnect IAC connector plug, EGR valve connector plug and EGR temp. sensor.
13. Stick something in intakes to prevent debris entering the intake ducts
14. PHEW !!!!
Like I said, ask for the relevant pages or e-mail me for more detail. Hope this helps. Cheers- Toyroom
>> Edited by toyroom on Wednesday 11th May 22:45
WOW .. this is one of the STUPIDEST designs ever!!! I'm so angry at how they made such a simple task a complicted and aggravating one. I've got most connections off, but still missing one damn bracket. I'm light headed from the gas fumes so I'm taking a break.
P.S- Thxs for all the replies guys.
>> Edited by V8TT on Wednesday 11th May 23:31
P.S- Thxs for all the replies guys.
>> Edited by V8TT on Wednesday 11th May 23:31
I'd hardly call it a stupid design... elegant and very compact, yes. I've removed the plenum a few times for cambelt servicing. It's NOT that difficult. I've said it before and I'll say it again... if you plan to work on the V8... BUY THE SERVICE NOTES!!!!!!!! They are relatively cheap and will save you a fortune in time and screw-ups.
The procedure is well outlined and does not take that long once you actually KNOW what you're doing.
Regards, KM
2000 V8
The procedure is well outlined and does not take that long once you actually KNOW what you're doing.
Regards, KM
2000 V8
V8TT said:
WOW .. this is one of the STUPIDEST designs ever!!! I'm so angry at how they made such a simple task a complicted and aggravating one. I've got most connections off, but still missing one damn bracket. I'm light headed from the gas fumes so I'm taking a break.
P.S- Thxs for all the replies guys.
>> Edited by V8TT on Wednesday 11th May 23:31
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