How to make the N/S plenum cover sit right

[rich17865]

Every single 75 or ZT I have seen has had the N/S (or passenger side) plenum grille sat higher than it looks like it is supposed to.

I have made mine sit correctly, it took about 5 minutes and anyone with a hacksaw can do it too.

The reason that the plenum cover sits high is because the securing tang on the thinner part of the cover fouls the rubber seal on the ECU splashguard.

1. Remove N/S plenum cover, then mark on the ECU splashguard where the hole that the plenum tang sticks through to secure it.



2. Remove the scrivet and three plenum clips that hold the top plenum cover on, and remove the ECU splashguard. You will now be able to see the two marks that you made to show where the plenum cover tang fits.

3. Cut away the upper section of the ECU splashguard seal, I used a hacksaw to cut down to the middle in line with the two marks I made, then used the hacksaw to cut out the unwanted top section, leaving the lower section intact. This will not compromise the seal that the ECU splashguard has with the plenum box.





4. Reassemble, when refitting the plenum cover I had to put it over the hob to heat it up as it needed bending back into shape just a little after 10 years of not fitting correctly.



5. Enjoy! You have completed a completely unnecessary mod that only you will ever see!

[Bolin]

Great stuff Rich, I've been thinking about doing this for a while - just seems odd that they obviously foul. You'd thought this would have been picked up at the design stage or rectified following the first production batch of cars.

Also, the bolt of the centre outer plenum wall sticks into the seal, and can damage it and makes removing/refitting the tray harder - I cut the end off the bolt and filed it smooth.

[dissy1810]

Or you could just put a shorter m6 bolt in the bulkhead the one at the top corner of the removable panel, as the one in there causes the lower shield to sit on the bolt sticking through so it sits higher stopping the top cover from sitting all the way down. If you remove the bolt you will see that every thing clicks into place

[CimmaronG]

Another 'To Do' job.

[Bolin]

Originally Posted by dissy1810

Or you could just put a shorter m6 bolt in the bulkhead the one at the top corner of the removable panel, as the one in there causes the lower shield to sit on the bolt sticking through so it sits higher stopping the top cover from sitting all the way down. If you remove the bolt you will see that every thing clicks into place

I found that with the bolt not protruding past the captive nut at all, and the lower shield sitting correctly, the top cover clip still fouls the rubber seal

Perhaps this comes down to 'manufacturing tolerances'.

[T-Cut]

I'm obviously not looking at it right places because my nearside grill piece sits down on the decking. Where do they stick up? Are there any photos of this misfit? I simply can't believe this was a design/manufacturing error. Isn't it more likely to be caused by some part not being fitted correctly? Sawing a chunk out of the seal surely can't be necessary, can it?

TC

[Time Searcher]

I've just checked my ZT-T (last 120 built) and the cover sits snugly without any modification, could this be a Mk.1 problem?

[lovema75]

Mine sits fine too and it's a fairly early one.

Of course like many things plastics warp with age, become more brittle etc.

And sometimes parts are just not stamped out correctly yet still make it onto the assembly line - poor quality control. ( I used to be a quality inspector!)

[rich17865]

I didn't take a before photo, perhaps someone else can provide one of theirs that won't close properly.

[KLM]

[IMG][/IMG]Heres a before piccy, after reading Riche's post i checked mine.


Here's the drivers side which sits in place OK.

[IMG][/IMG]
Kevin.