Need help pulling plenum...!!!

[Norsky4360]

I'm attempting to replace the injectors and I'm stuck at the moment. I've disconnected everything I can see on the topside and have pulled as many torx head bolts that I can see holding the plenum on. But the dang thing seems to be welded on...!!! What am I missing...???

Any help would be appreciated. I'll return call if a phone number is PM'd to me.

Thanks!

[ROGER E]

Just pulled mine off today....about the 15th time. Is it even loose? All the torx that hold it on are from the top...6 per side 12 in all. Hit it with a rubber hammer or a peice of wood from the side to crack it free.

[Locobob]

http://www.pnwzr1.net/PNWZR1.htm

Look at LT-5 tear down part one and also the 94 plenum articles under the tech section heading, should help you out some.

[Norsky4360]

Thanks guys!

It won't budge by hand. That's why I thought I'd missed something. To the best of my knowledge the plenum has never been taken off. There's just under 8k on the odometer and the only repair tickets I've been able to dig up (we're the 2nd owners) have been for minor things (oil changes, etc).

I've taken out the 6 bolts on either side, disconnected all the electrical connections, and have all the hoses pulled that I can see and reach (except the one on the front left - no wiggle room on that one until the plenum is loose). I've disconnected both fuel lines and a bracket by the firewall holding a little black box. So I guess it just needs a little love tab to come loose.

Robert - thanks for the link...!!! Last night while looking for tips I saw that site/tech article referenced by name (no link tho') but couldn't find the right site before I posted my call for help. I'll be printing it and the photos before heading back out to the garage.

Tally ho..!!!

[bldavis11]

Do you have it off yet? I'll send a PM with my contact information.

[Norsky4360]

Thanks again for the help, and most of all - for the moral support...!!!

It took a lot longer than I expected, probably because I was venturing into new territory, but "The Beast" is back together - AND RUNNING...!!!

The "love tap" with a chunk of 2X6 on each side of the plenum did the trick and it popped free. Then the "fun" began. That rear connector secured by the 1/4" bolt is a real P.I.T.A. to get at. Not only to loosen and unplug but to reconnect and tighten down.

The left side of the fuel rail was real easy to get free. Didn't take much pressure from a pry bar to get all 8 of the injectors loose. The right side though wasn't as nice. All 4 primaries didn't want to budge and as a result I had bent clips to straighten out and a little fuel dribble out. All 16 of the old ones were a real dirty mess. Spent about an hour cleaning out the injector holes with Q-tips. The new Accel injectors fit into the fuel rail very nicely and everything went back together quite easily (except for the afore-mentioned connector! ).

Once all buttoned up it cranked for a few seconds more than usual on the first start but quickly idled out real nice and smooth. After cleaning up a bit I took it out for a test drive and am happy to say it pulls hard and smooth up to the century mark (that's where I had a reality check - a warm night after dark on a country road means critters are moving about) so reeled it back down to 5 over the posted limit.

Thanks again!

Jim


btw - #1 cylinder had the failed injector. Total failure. I should have written down the numbers on the others as there was quite a spread.

[tomtom72]

Way to go Jim!

It is a lot of busy work but as you now see there is actually not much to be intimidated by! It's a question of all the other standard cars we have ever worked on and how the LT5 "Looks" soooo much more complicated and different.....but it's still an intake manifold when all is said & dunn.

Enjoy your baby!

Tom

[A26B]

Good Job!! Well Done!!