Coolant leak under the plenum

I've remember stories of small parts which come under the influence of gravity when the plenum screws are removed. If one isn't super careful, they can fall into the intake valves, which might ruin one's day.

Here is the prime thread to read first http://www.ferrarichat.com/forum/showthread.php?t=16536

FYI, search is your friend but the words are key. I found the thread I recollected by looking for 'plenum remove'

 

This be true.

If you are going to take the plenum off frankly its not that much harder to remove it with the manifolds as one unit and then you remove his risk. The things that drop are small spacers & there are 8 of them to watch out for. WIth just the plenum removed to be honest your access to the coolant pipes underneath is still not great

If you want to remove it as one then disconnect the fuel lines from the injectors, remove the throttle body, disconnect all the other pipes & the throttle cable from it & then the key is to loosen but not remove the 8 nuts under the plenum that secure it to the manifolds. Then undo all the manifold nuts & bolts & there should be enough play in the assembly to allow you to remove the whole thing with much less risk of dropping anything down a manifold/inlet port. When undoing the manifold nuts have a maghnetic pickup tool handy to help get the nuts out & the washers off without dropping any.

Once its off then tape over the inlet ports before you do anything else. This will give you the best possible access to get to the coolant pipework underneath.

 

I had to replace the hoses under mine. Just be cautious when removing the plenum, there are some washers "under" there that usually stick to the underside of the plenum that could drop into the intakes. Getting them back in alignment to install is fun. Fishing the throttle cable through during reassembly is a lot of fun too. Make sure you go straight thru to the other side. Replace ALL of the hoses while you are in there. Lots of time bending over! lol My back hurts thinking about it. good luck

 

YES !!!!

There are 2 thick washers (Cylinder-shaped actually) in each of the four very visable black rubber gaskets that sit between the air box on top and the plenum "risers."

DO NOT drop any of these inside the motor. It is darn easy to do. Lose one or more and EVERYTHING MUST come to a stop and it MUST be located and secured. I almost always "lose" one ......

IIRC they are magnetic. My box is off now and I'll check tonight if you wish.

 

Some have seen my newest RobzWorkz coolant post. In there, I didn't show replacing the coolant gaskets at the intake area. This is because I will need to remove the intake to do so. Since I had to get the 328 running so that I could get emissions tested, I deferred this part until later, when I replace my fuel injectors and bushings. I will post this process in the coolant post "when I get there."

For now, you should remove and refurb the intake: remove just above the engine, where the eight smaller gaskets are located (replace them). I can't say more about the intake plenum and the tube nor the throttle body and cable yet, but I do know that you will want to stuff rags into the intake holes to prevent admitting stuff into there.

Good luck and post pics.
Rob H.

 

I recommend having a shop vac with self-made small nozzle to suck out any bits. Recover in the vac to keep track...and don't forget to put back, Jack.

 

I'll give you a little tip.

It's a hell of a lot easier to replace the two hoses under the plenum by leaving the damn thing right where it is and going in from the end though the right side (passenger side on a USA car) wheel well.

If you want to make it ridiculously easy, remove the water pump. But you can do it with the WP in place as well. I personally think that pulling the WP and rebuilding it at the same time is the best way to do it. With the WP out, it's very simple to replace those two pieces of hose and the clamps. And if you are doing coolant anyway, you might as well address the WP. You have to drain the coolant to replace those hoses unless you want to make the mother of all messes in the engine so what the heck...

Birdman

 

My 1st time I did the job by removing the plenum - very nervous about the washers - almost lost one down the intake - stopped and looked for 45min until we found it - thank God - it was under the wires that cross over the top under the plenum -

My 2nd time I did it by the WP side and it was much easier with the WP out and on the nerves too - just cover the t-belt openings so "odd stuff" does not wonder in there - the PVC hose could also be removed and replaced to give you somemore room in there -

Good luck either way!!!

Wayne

 

This is how I did it. There is no easy way. Take a lot of time and it can be done either way. The hardest one to get on my car was the hose from the overflow to the center of the valley. It's hard to get so it's frequently original. Here is what mine looked like when it came out. Believe it or not this did not leak, but it had crystalized green all over it.
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