My plenum thread!!!

[DAEDALUS]

The EGR pipe you can probably wiggle back and forth about 10 degrees. This will loosen it up a bit and you may be able to undo the flarenut at the bottom of the pipe with your hand.

[elwesso]

Robert- Do you think Ill be able to reach down there and loosen it up?? I can move the pipe a good distance.... maybe 6in laterally..... Its really loose, and Ill try it again tomorrow....

I have the valve cover off but not out of the car because of the EGR....

Also, how the hizzle do you get to the knock sensors... I realize you must get those hoses off, but arent those metal coolant things in the way??? Boy as soon as I slit those its gonna open the flood gates!!!

How am I ever going to get this thing back together.... Hopefully it wont be as hard as removal, because now I know where everything goes... I probably wont bother with some of those worthless brackets and stuff like that...

One thing for the people reading this: Get all those little tiny vacuum hose and coolant hose, the itty bitty ones with no clamps... Fortunately, we have a bunch of that stuff laying around the shop (a good 6 feet), so I got lucky.

[911/Q45]

I just bent the EGR pipe out of the way and bent it back later with no bad effects. Unbolt the coolant necks in the valley and remove them and the hoses as a unit, then put them back in the same way. They seal up with RTV. Some of the vacuum hoses are molded with sharp bends, so you may not be able to use stock hose. Try your best to reattach all the brackets to avoid future mystery problems and rattles. What did the final hangup on the plenum turn out to be?

[elwesso]

There was a bracket holding something on in the back, I think it held a connector of some sort... I didnt think about what I was removing, I just did it...

Also, I might as well take the EGR pipe off since im going to have to take it off, since its really loose.... Maybe im wrong..... Ill try that, but with my luck Ill break it....

Im gonna have to call Joe on Monday to figure out what the deal is with those tiny hoses... Im sure for some people they break like noodles.....

Also, I am having a heck of a time with the drivers side plastic cladding cover..... The one on the front, covering the VVT solenoid thingy.... again, I have to deal with tiny hoses going to the carbon canister, and I dont want to pull or cut them.... How did you get the plastic thing off??

[elwesso]

Oh, I thought id throw this in too...

INJECTOR OHMS

All within spec

1. 12.22. 11.33. 11.24. 11.45. 11.16. 11.27. 11.28. 11.6

THats from memory so Ill double check those from my notes tomorrow (its in the shop).... I know no1 was 12.2, and all the rest were in the 11's... Does this mean I have healthy injectors???

[911/Q45]

I just removed the whole carbon canister and replaced all the hoses involved with it. They are all stock sizes, so you can do it cheaply. Good ohms mean the injectors ar probably all good electrically, doesn't address how gunked up they may be or what happens when they are a different temperature or vibrating.

[DAEDALUS]

Snake your hand down along the EGR pipe till you get to the nut at the bottom of it, then see if it'll unthread by hand. Unfortunately reassembly is not easier than disassembly, but for different reasons.

[elwesso]

How will I tighten the EGR tube once I need to put it back on??? I lifted the car up, and looked under there and I could hardly get my hand in there, let alone tools...

Does anyone know if that little round thing on top of the carbon canister comes off??? Or am I gonna have to replace all that stuff???

[DAEDALUS]

Once it's off you can measure the size of it. I forget what it was, maybe 19mm? I think I just tightened it by hand and then used a stubby wrench to finish it up. From above though, not from below. I don't recall having to take anything off the carbon cannister to remove it. Disconnected 3 hoses and the clamp is all I recall doing.

[elwesso]

Thanks.... I worked around it, and the drivers side cover is resealed!!!! I dont have to worry about the plastic cladding anymore....

Unfortunately my torque wrench only went to 15 ft/lbs, and it called for 10.... Hopefully it wont be a big deal that its too tight......

See my other thread with pictures with the covers off.....

[DAEDALUS]

The fasteners used are the smallest ones available that still provide enough clamping force. Going 50% high on the torque value is a recipe for broken fasteners. Better to hand torque it nice and snug IMO.If the EGR tube was loose how do you know the nut on the bottom is tight? If the nut was tight, I don't think the EGR tube would have any play in it.

[elwesso]

I was referring to the bottom nut that was loose.... I got the whole thing out really easy.... Now I gotta put it back on

And for the torque on the valve covers, thats basically what I did... I set it at the lowest setting (My guess is around 10) and left it at that... I think thats fine.....

Boy, Ill tell you what I dont know how they got that whole Y shaped assy that covers the knock sensors.... Ripping it out was easy enough, and KS replacement was easy, but getting that thing back in was a dilly of a pickle... It sucks because you have to put it in there in one piece.... I had to twist the left hand bank part sideways and shove it in there..... Anyone know a better way of doing it, for the next person??? Now I pray to god that it doesnt leak, or I might get a new engine (might not be too bad since mine has been abused )

I have partially decided not to reseal the passenger side cover at this time, since it doesnt really require the plenum to be off, and Id rather ot prolog the agony more than I have to... Or should I do it??

At this point, Im so sick of this I wanna get the plenum back on and this GDAM thing running again!!!

[nuQ]

OUCH!!!! hate to say this, but,,,,,THANK GOD I WAITED FOR THE GUINEE PIGS!!!!! wes, i think you've convinced me to let someone else deal with all this!!!! i think this is all out of my world of expertise!!!! i really hope it all gets put back and runs right!!!

[elwesso]

Jeff.... Its not really as bad as it sounds, I am just really sad and sour right now, from seeing all the sludge in my heads (both of them), so i might be exaggerating....

As long as you can handle cuts on your hands and you have something you can throw to aleviate frustration, youll be fine.....

Just to give you an idea of what this is like, if youve done the plugs before, multiply this by 10 and your about at the plenum.....

I STILL THANK GOD THAT MY HOSES ARENT CRACKING SO I HAVE TO REPLACE EVERYONE..... So far ive only replaced ones I couldnt get off..... All the other ones are just fine..... It now al depends on how much will power I have to replace the rest.....

[nuQ]

hang in there brother, my thoughts are with ya!!!!! i'll still wait till it's all done! Jeff

[90Q45blue]

Keep up the good work Wes. You're Almost done.

Nick

[Rex]

So whats the $$ diff between Wes' (Cravens??) nightmare or taking it and the parts (Joe's da man) to T3 for a full day of fun?

Time to start doing the math.

[elwesso]

Rex.... So far this job has cost me just a bit over $500 (all parts).....

Id say well over 3 grand to take it to T3 and do it as good as im doing it....

Ok... Now for another question.... Plenum re-installment should commence today... Right now im cleaning the runners.... but something occurred to me.... Ive just been spraying carb cleaner down there and wiping it up (most runs down the runner)... Would the best thing to do be when I get done to crank it a few times with the injector and fuel pump fuse out???

[Q45tech]

How accurate is your VOM and where are you measuring the resistannce..............the 11 ohms seems a little low.

I measured 3 brand new ones they were 11.9-12.0 and all 12.2 on two different medium priced [$200] VOM.

My $1000 ohm meter measured all 3 at 11.930-12.087 ohms.......

why I say 11.8-12.2 ohms............use a brand new battery in your VOM and make sure the shorted leads read 0.000 ohms.

[Q45tech]

The two hoses that feed the IAC are the usually last to be freed.Your remove the TB/EGR before the plenum.

Yes Virgina you have to remove the metal coupling from the heads to Large coolant hoses to get the KS out.

You replace the large hose and metal couplings as a single combined unit......don't forget RTV back to heads and correct torque on all bolts many break plenum bolts from too much tightening force.

What an education the plenum is!

[Qdemption]

Here is a picture of the v area. There are other pictures in that gallery as well that pertain to the plenum.

http://www.nissaninfiniticlub....age=1

I had a stroke of good fortune yesterday when I took a break and tried out this leather condition for the interior I recieved for x-mas. I found a 92 Q45 FSM. I had it all along?!?!

[elwesso]

Oh jesus dude, dont do anything until you plug up the runners!!! You will start crying if you drop something down there... As soon as my plenum came off, paper towels went in there (thick ones).... Looks about like mine, except the big hoses had screw type clamps not the evil spring compression ones (I may switch to screw type since they are so much easier)...

Im pretty sure that all G50 Q came with a FSM in the trunk.....

[elwesso]

Q45tech... I have a $20 walmart digital meter.... Nothing like what you would have..... I may replace the battery and retry before I throw the plenum back on....

I still have to undo the IAC hoses that I cut..... Boy that is hard to get at.... Does the o2 sensor harness disconnect from the metal tubes.... It would be much easier to replace the hoses that way with that assy out....? I dont wanna break anything and im not sure if it is supposed to come out....

So far, Ive been following all the torque pretty close..... All the major things I have followed to the T..... I even retorqued my spark plugs....

[DAEDALUS]

Looks about like mine, except the big hoses had screw type clamps not the evil spring compression ones (I may switch to screw type since they are so much easier)...

Maybe this is why your hoses are in such good shape? Sounds like maybe the plenum has been off before?

Qdemption, your picture of the clean valve cover surrounded by about 600 dirty Qtips is very amusing!

[elwesso]

Robert.... I have been thinking the same thing..... On that <evil cursed> hose that plugs into the plenum right in front of the IAC, that hose had a screw type clamp too.... The only vacuum hose that had this..... I switched to screw type clamps on a few hoses to make it easier next time......

If I recall, on my service record the no 7 injector has been replaced under warranty... Maybe they replaced hoses too!!!!

[elwesso]

Well..... I have good news.... The worst is over... I probably have about an hours worth of labor yet to get the car running..... Installation was a breeze, and ive just been working my way around connecting things.... All i have left is a little cluster of tiny hoses on the front right part of the plenum (cali models only??), and the hoses near the TB, reattach the EGR and TB.....

IMO the installation was much easier than taking it off, mainly because I know where everything is and how it comes together....

For all the plenum virgins out there, you think its hard when you start, but when you go to reassemble its not that bad at all..... Believe me, when they say there is a learning curve involved, ITS TRUE!!! I think I could yank that thing off in no time (its not gonna happen for a while though)...

[elwesso]

Coincedentally, I only ended up using a few of the hoses.... Thankfully Ill be able to send most of them back....

Next time I do the plenum (LOOONG way away), I will remove the runners as you basically have to remove them in order to access some of the hoses.....

Also.... How do you all re-tighten the EGR tube on the exhaust manifold.... I can hardly squeeze my hand in there (top or bottom)....