I am finalizing install instructions this weekend to ship out with the plenums, but for anyone who has their plenum already, or theirs is on the way, here are some key tips to follow.

Hardware supplied

4 - short button/allen head screws - used inside the plenum to plug the 4 unused bolt holes

2 - long button/allen head screws - attach the coolant block
2 - support posts with threaded ends
2 - flush mount allen head screws (threaded into center supports)
2 - long hex head black screws (may be allen head if earlier packed) - used for the rear 2 engine cover points
2 - white nylon spacers - used underneath the rear 2 engine cover mounting points
12 - washers - use under each main flange bolt
1 - tube of threadlock

Install the 4 short button head screws into the 4 holes that are left by the factory plenum supports, leave the center 2 holes untouched. These screws should be tightened firmly with a tiny drop of threadlock on each screw.

the longer center support screws into the rear center hole, and the shorter into the front hole, hand tighten these firmly.

Do not remove the factory gaskets, they are to remain and still be used

Use a washer underneath EVERY bolt that goes around the flange, 12 total.

Start each bolt with about 2 revolutions to get the threads started. Get ALL of the 12 bolts started before tightening any of them. Make sure to use a drop of threadlock on each bolt.

1 by 1 tighten down the bolts very slightly each, go all the way around, then go around again and give it a snug fit tightening.

DO NOT use anything larger than a 1/4" ratchet or even better, use a nut driver (looks like a screwdriver, but has a 10mm socket)

A torque wrench is BEST, and should be set at 36 inches/lb or less.

The center 2 flush mount screws can be tightened down with more firmness.

Start the car and let it idle. Go under the hood and listen for any air leaks, they will most likely be audible if there are any. You may also run your fingers around the flange edge and listen for audible differences.

If you find a leak, tighten the surrounding bolts in the entire section of the plenum, starting with 1/8 turns.

Once you have verified there are no leaks, turn the car off and let it sit for at least 30 minutes to let the threadlock set in.

The throttle body bolts may also be tightened firmly.

Lastly, I may be emailed at jamisonl@msn.com for any questions, I check this email VERY often.

 

[crying] But..... I thought you said that you liked MY instructions? "Whaaaaaaaaaahhhhh!!!" [/crying]

Hehehehe!

-Chrismcagle

 

I will be using your instructions, and almost all of your pictures, then I will put together something I can include in the shipment.

 

Well I didn't use the nylon spacers or the two bolts as I wasn't sure which were the rear holes that needed them since all original bolts went back in.

Another place to check in addition to Chris' suggestion of the coolant block for free passage is the brake boost FITTING!!! there is nothing like taking it for a spin and finding yourself without brakes. I came back and took the fitting off to find it completely plugged up.

Now I have brakes but still have a leak that I cannot get rid off, it is right in front at first I could feel it pull on my skin when I put my finger on it and you could see the gasket wasn't seating flush, I thought maybe it was my paranoia of craking the plenum and hadn't tightened it enough, I kept tightening and running the car it got better every time but now I am to the point where the plenum is cracking and the leak is so fine that it emits a loud whistle and I can't get rid of the leak, I am trying some sealent to see if that will fixed it but not happy.

 

Yeah, I was just giving you a hard time!

Just make sure you you get a "current" version of the instructions because I seem to tweak them daily. A word here, a sentence there. Just want to make sure it's crystal clear.

-Chrismcagle

 

Where on the plenum is the "Brake Boost fitting"?? Mine must be fine because my brakes work great, but it might be something worth noting on the instruction site. Let me know

-Chris

 

When looking at the engine from the front it is the fitting that is on the left (passenger side) that the hose hooks into and goes towards the battery compartment.

Yours must be fine, trust me you would know if it wasn't, might be worth to flash alight in ther and see to make sure it is not partially plugged.

When I got back I stuck a hanger into it and it didn't go in so I checked with a flashlight and could see the epoxy or glue , so I took it out and removed the stuff and then it was fine, but no fun finding that out. I am glad it takes a mile to get out of my development so I wasn't going over 30.

 

Could the plenium mold be modified to have some sort of metal insert around the bolt holes to help with this cracking/low torque issue? Or some sort of metal gasket be made to fit over the top of the plenium and placed on top of the plastic lip in order to help distribute the stress?

 

When I get home I will definitely take a look at mine (I'm sure it's fine, but maybe there is a slight blockage, who knows). I'll also take a couple pictures and document it on the instruction site as something else to check before installing. I am extremely positive that lsdunique is fixing all these problems as they are presented so that future units don't have the same issues, but as they say... knowledge is power.

-Chris

 

Look for an official post regarding what we have in the works for a higher torque rating.

 

Chris, your link to plenum instruction is DOWN. Earthlink problem, or something. Can you forward to my email?

rescomoperations@megapathdsl.net

thanks!

Are you up for a meet on thus/friday of this week? I had started a little group, and got a lot of responses.... if we both push it, we could have like 15-20 cars!

let me know

 

Hmmm... that's the old link. The new link to the plenum install instructions are in my signature. Or you can go here. Keep in mind that these are for the V1 and V2 (I have not updated them since they are all mostly the same. The only difference will be the center supports are no longer used).

Good luck. As far as a meet, what do you mean? Are you talking about lunch or something else?

-Chris

 

Heh, I've changed plenums so many times I could do it with my eyes closed by now, but those sound like great instructions.

OT: When is that y-pipe coming out? I'm patiently waiting on it.

 

Chris, please add an important reminder to do this "once the engine has cool off significantly". I kept burning my arms, just because I couldn't wait to install the stupid thing..... lol....

 

Oooooo... good tip! I'll have to edit the site immediately!

 

Chris, I was talking about an evening/weekend meet....so everyone has a little more time. A local group together to exchange mod ideas(i want to look at different power boost options) would be cool.

It's fun to help the greenies out there just getting started modding, and show of your own perfected product of hard work.

Also, want to do a 'drive' in canyons/beach, etc... with a group of z's!

We talked about it on the thread last week getting 818/805/661 area codes a little get together. I received a lot of responses in my personal email address. You don't recall?

 

oops...

 

Ahhhhhh.. got it. Yeah, I'm up for a meet sometime... well, anytime actually.