4. 1/4" Drive 2" socket extension
5. 1/4" Drive T30 Torx bit
6. 1/4" Drive universal joint
7. Targa-Top removal tool (T40 Torx)
8. T15 Torx Driver or Socket
9. Several shop rags
10. A container to catch drained coolant
11. Magnetic Pickup tool (you never know :-) )
---Materials---
1. (2) Plenum gaskets (You can reuse the gaskets presently on the car if you can remove them without damaging them)
2. About 12 ounces of 50/50 water/antifreeze mix
---Procedure---
1. Loosen the coolant cap (1).2. Place a rag under (2) and then remove the hose from (2).
3. Place the end of the hose removed in step 2 into the a container suitable to collect coolant.
4. If your container gets full simply raise the end of the hose above the plenum, empty your container, and then continue. I usually empty it into the overflow tank (front right fender well) and let a few heat cycles suck it back into the system. You should keep draining the coolant this way until no more will come out.
5. Using the flat-blade screw driver carefully remove the vacuum hose (3) from the plenum.
6. Loosen the clamp (4) retaining the air intake duct.7. If you have a later model w/ egr you will need to remove that connection at this time.
8. Place a rag under the coolant connection at the right-rear of the plenum (5) and then remove the hose.
9. Remove the evaporative vapor canister purge hose
and then release the connector holding the plastic line from the bracket attached to the coolant line. (6) - (Not shown as I have removed mine)10. Remove the electrical connection for the idle air control solenoid (7).
11. Remove the passenger-side crankcase breather hose from its connection to the throttle body extension (8).
12. Remove the electrical connection for the intake air temperature (IAT) sensor (9).
13. Remove the power brake booster vacuum line (10).
14. Remove the fuel pressure regulator vacuum line (11).
15. Remove the molded PCV hose from the metal vacuum line (12).
16. Using a flat blade screw driver carefully remove the vacuum connection from the driver's side of the plenum (13).
17. Remove the electrial connector for the throttle position (TPS) sensor (14).
*** Perform steps 18, 19 & 20 only if you need to completely remove the plenum from the car (for porting, painting, replacement, etc). If you only need access to the under side of the plenum these steps are not necessary. ***
18. Using a T15 torx driver, remove the clamps holding the throttle cables to the plenum (15).
19. Using a T15 torx driver and a 1/4" socket remove the nuts and bolt holding the throttle mechanism cover. (16) Remove the cover.
20. Using the flat-blade screw driver while moving the mechanism by had carefully remove the cruise control cable and the throttle cable from the throttle mechanism (not shown).
21. Using the T30 torx socket with the universal and an extension, remove the bolts holding the manifold absolute pressure (MAP) sensor bracket (17). Simply let the bracket / sensor slide towards the firewall and out of the way.
22. Using the targa-top removal tool, remove the 12 bolts holding the plenum to the injector housing in the order shown to the right.
23. Carefully lift the passenger side of the plenum and work the gasket loose. Remove the gasket. If undamaged, identify its location and orientation for reuse.
24. Repeat step 23 on the driver's side.
26. Lift the plenum from the passenger side and carefully remove the remaining electrical connectors (19) from the ignition module. You may need to use the screw driver to help pry the clasps on the connectors. Be careful as they are probably brittle from heat.27. Lift the front of the plenum from the driver's side to remove the vacuum hose that supplies the evaporative canister purge system (20). The connection is capped on my car since I removed that system.
28. If you performed steps 18-20 you can remove the plenum from the vehicle. If not, simply lay it over towards the driver's side as shown.
29. The driver's side crankcase breather tube (21) kind of removes itself during plenum removal. Make sure it seats properly when re-installing the plenum.
30. Cover the plenum runner openings and the injector housing openings with shop rags or 2" wide masking tape to prevent debris from entering.
31. Re-installation is the reverse of removal. Torque the plenum bolts to 19 lbs/ft (as tight as you can get them with the targa-top tool) in the order shown below. Be sure and replace the coolant you drained during plenum removal (unless you already put it in the overflow tank).
