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Thread: Have to remove two-piece upper plenum

  1. #1
    boostaholic Turbo Mopar Contributor
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    Have to remove two-piece upper plenum

    I need to pull the top intake manifold piece off and am wondering about taking the front mount loose and rotating the engine forward for access. Will that work? It's too close to the firewall as it is to get any kind of wrench or socket on it.
    [SIGPIC][/SIGPIC][FONT=Comic Sans MS]'91 Shadow convertible 2.5 auto, three core RP IC, S60/.48 stg 1, ported two-piece intake/52mm TB, Menegon +1 swirl, 88 turbo cam, Venolias, Crower rods, TU deep sump pan, ported exhaust, 3" from SV to TP, Hughes TC, Peloquin diff, DSS L5 driveshafts, Shelgame cal, Koni struts/shocks. [/FONT]

  2. #2
    turbo addict
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    Re: Have to remove two-piece upper plenum

    If you want an inch or so, then should do, if you're trying to get an air impact on it, not so much.
    DD1: '02 T&C Ltd, 3.8 AWD. DD2: '15 Versa Note SV, replacing.. DDx: '14 Versa Note SV << freshly killded :( ....... Projects: '88 Voyager 3.0, Auto with shift kit, timing advance, walker sound FX muffler on 15" pumpers wrapped in 215/65/R15 H rated Nexens.... and a '95 phord escort wagon PnP head << Both may need to go :( ..... I like 3.0s ... so??? ... stop looking at me like I've got two heads!

  3. #3
    boostaholic Turbo Mopar Contributor
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    Re: Have to remove two-piece upper plenum

    I just need to get anything on the bolts to remove the upper piece so I can get to the &*^% WG actuator clip.
    [SIGPIC][/SIGPIC][FONT=Comic Sans MS]'91 Shadow convertible 2.5 auto, three core RP IC, S60/.48 stg 1, ported two-piece intake/52mm TB, Menegon +1 swirl, 88 turbo cam, Venolias, Crower rods, TU deep sump pan, ported exhaust, 3" from SV to TP, Hughes TC, Peloquin diff, DSS L5 driveshafts, Shelgame cal, Koni struts/shocks. [/FONT]

  4. #4
    Moderator Turbo Mopar Staff Turbo224's Avatar
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    Re: Have to remove two-piece upper plenum

    Wow, that seems like a lot of work just to get that clip off. Sore you cant just pop the clip off there with a really small flat head screw driver?

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  5. #5

    Re: Have to remove two-piece upper plenum

    Quote Originally Posted by Turbo224 View Post
    Wow, that seems like a lot of work just to get that clip off. Sore you cant just pop the clip off there with a really small flat head screw driver?

    Agreed. You don't need to do that to get it off. To get it on, that's a whole other issue. Cordes gave me one (THANK YOU!!!) that is elongated and can EASILY be pulled off or put on. It's basically a clip that functions like an e clip, but looks like a paper clip. Similar to this, but a little longer.

    Click image for larger version. 

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    [SIZE="3"] [B]Jon Trotter[/B][/SIZE] [B]1985[/B] Dodge Shelby Charger, Currently decommissioned [B]1987[/B] Shelby GLHS, #937 [B]1987[/B] Shelby Lancer, #628 [QUOTE=Reeves;587010]I can be ready. Please send pics of wife. _____DodgeZ add comments here______[/QUOTE]

  6. #6

    Re: Have to remove two-piece upper plenum

    Quote Originally Posted by John B View Post
    I just need to get anything on the bolts to remove the upper piece so I can get to the &*^% WG actuator clip.
    It's much easier to remove the swing valve/can assembly than the plenum (assuming the bolts aren't frozen). Fewer bolts and better access.

  7. #7
    Super Moderator Turbo Mopar Staff contraption22's Avatar
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    Re: Have to remove two-piece upper plenum

    Quote Originally Posted by minigts View Post
    Agreed. You don't need to do that to get it off. To get it on, that's a whole other issue. Cordes gave me one (THANK YOU!!!) that is elongated and can EASILY be pulled off or put on. It's basically a clip that functions like an e clip, but looks like a paper clip. Similar to this, but a little longer.

    Click image for larger version. 

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    That style clip works even better if when the swingvalve has a hole in it that you can put the clip through.
    Mike Marra
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  8. #8
    Buy my stuff!!!!!!!!!!! :O) Turbo Mopar Vendor turbovanmanČ's Avatar
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    Re: Have to remove two-piece upper plenum

    You should be able to access the clip by removing the throttle body and hoses, I did an oil line by doing that.

    To remove the upper plenum bolts, I just used a long extension and a swivel 13mm socket going up thru the bottom of the engine.
    1989 FWD Turbo Caravan-2.5 TIII, GT35R, auto, a/c, cruise, pwr windows/locks, fully loaded with interior and ran with full exhaust. RETIRED FOR A FEW YEARS! 12.57@104 :O)
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  9. #9
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    Re: Have to remove two-piece upper plenum

    Dunno if it works in this case, but I've had a lot of luck on other back of block "reacharounds" by pulling out the battery and using that space to get my arm in.
    DD1: '02 T&C Ltd, 3.8 AWD. DD2: '15 Versa Note SV, replacing.. DDx: '14 Versa Note SV << freshly killded :( ....... Projects: '88 Voyager 3.0, Auto with shift kit, timing advance, walker sound FX muffler on 15" pumpers wrapped in 215/65/R15 H rated Nexens.... and a '95 phord escort wagon PnP head << Both may need to go :( ..... I like 3.0s ... so??? ... stop looking at me like I've got two heads!

  10. #10
    boostaholic Turbo Mopar Contributor
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    Re: Have to remove two-piece upper plenum

    Quote Originally Posted by Turbo224 View Post
    Wow, that seems like a lot of work just to get that clip off. Sore you cant just pop the clip off there with a really small flat head screw driver?
    Tried many times. No go.

    ---------- Post added at 01:11 PM ---------- Previous post was at 01:09 PM ----------

    Quote Originally Posted by turbovanman View Post
    You should be able to access the clip by removing the throttle body and hoses, I did an oil line by doing that.

    To remove the upper plenum bolts, I just used a long extension and a swivel 13mm socket going up thru the bottom of the engine.
    I'll check into that and see if it'll work on mine. Thanks for all the tips guys!
    [SIGPIC][/SIGPIC][FONT=Comic Sans MS]'91 Shadow convertible 2.5 auto, three core RP IC, S60/.48 stg 1, ported two-piece intake/52mm TB, Menegon +1 swirl, 88 turbo cam, Venolias, Crower rods, TU deep sump pan, ported exhaust, 3" from SV to TP, Hughes TC, Peloquin diff, DSS L5 driveshafts, Shelgame cal, Koni struts/shocks. [/FONT]

  11. #11
    boostaholic Turbo Mopar Contributor
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    Re: Have to remove two-piece upper plenum

    Got the upper piece of the manifold off. I still can't get the clip out! So, the head is coming off again. Oh bother!
    [SIGPIC][/SIGPIC][FONT=Comic Sans MS]'91 Shadow convertible 2.5 auto, three core RP IC, S60/.48 stg 1, ported two-piece intake/52mm TB, Menegon +1 swirl, 88 turbo cam, Venolias, Crower rods, TU deep sump pan, ported exhaust, 3" from SV to TP, Hughes TC, Peloquin diff, DSS L5 driveshafts, Shelgame cal, Koni struts/shocks. [/FONT]

  12. #12
    Buy my stuff!!!!!!!!!!! :O) Turbo Mopar Vendor turbovanmanČ's Avatar
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    Re: Have to remove two-piece upper plenum

    Damn, your going to get the head off and it will simply slide off, lol.
    1989 FWD Turbo Caravan-2.5 TIII, GT35R, auto, a/c, cruise, pwr windows/locks, fully loaded with interior and ran with full exhaust. RETIRED FOR A FEW YEARS! 12.57@104 :O)
    1984 Chev Getaway van, 6.2 Diesel with a remote mounted turbo setup burning WMO-For sale.
    2003 GSW 2.0L TDI, auto, fully loaded, modified, 360K-wife's.
    2004 GSW TDI, 5 speed, fully loaded, modified.

    Aurora ignition wires for sale. Link to info

    Super60 roller cams or custom/billet cams. Link to info

  13. #13

    Re: Have to remove two-piece upper plenum

    Can you provide some context as to why you're pulling the actuator off? I'm sorry but to pull the head to remove the arm seems unnecessary, to say the least for the work and cost associated. That's like pulling the motor to replace the timing belt. Can you snap a picture of it with your phone? This thing must be one solid piece of rust to be so stubborn.
    [SIZE="3"] [B]Jon Trotter[/B][/SIZE] [B]1985[/B] Dodge Shelby Charger, Currently decommissioned [B]1987[/B] Shelby GLHS, #937 [B]1987[/B] Shelby Lancer, #628 [QUOTE=Reeves;587010]I can be ready. Please send pics of wife. _____DodgeZ add comments here______[/QUOTE]

  14. #14
    boostaholic Turbo Mopar Contributor
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    Re: Have to remove two-piece upper plenum

    I'm removing the actuator because the diaphragm melted in an engine fire. I can't get the "e" clip out without removing the head to get at it. All the grief I've gone through trying to avoid pulling the head has been more work already than pulling the head, so to heck with it. Off it comes. I have a new set of ARP studs to put in anyway.
    [SIGPIC][/SIGPIC][FONT=Comic Sans MS]'91 Shadow convertible 2.5 auto, three core RP IC, S60/.48 stg 1, ported two-piece intake/52mm TB, Menegon +1 swirl, 88 turbo cam, Venolias, Crower rods, TU deep sump pan, ported exhaust, 3" from SV to TP, Hughes TC, Peloquin diff, DSS L5 driveshafts, Shelgame cal, Koni struts/shocks. [/FONT]

  15. #15
    Moderator Turbo Mopar Staff Force Fed Mopar's Avatar
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    Re: Have to remove two-piece upper plenum

    I would just remove the turbo. It's not as bad as it looks/as everyone says. Unless of course you have DodgeZ's luck lol.
    Rob M.
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  16. #16
    Rhymes with tortoise. Turbo Mopar Staff cordes's Avatar
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    Re: Have to remove two-piece upper plenum

    Quote Originally Posted by minigts View Post
    Agreed. You don't need to do that to get it off. To get it on, that's a whole other issue. Cordes gave me one (THANK YOU!!!) that is elongated and can EASILY be pulled off or put on. It's basically a clip that functions like an e clip, but looks like a paper clip. Similar to this, but a little longer.

    Click image for larger version. 

Name:	How-to-make-RC-car-body-clips.jpg 
Views:	117 
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    I just found one in the garage the other day which is stainless. Talk about the way to go...

    As to the matter at hand, I can get an E clip on and off a motor with a two piece in an L body with enough patience. The clips that Jon has posted take a couple seconds to get on and off.

    It's amazing how quickly you can get stuff done after doing it a couple of times.

  17. #17
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    Re: Have to remove two-piece upper plenum

    a dental pick or hook will pull the clip right off by reaching around the motor on the passengerside, no need to pull anything off.

  18. #18
    boostaholic Turbo Mopar Contributor
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    Re: Have to remove two-piece upper plenum

    I don't doubt for a moment that any number of you on this forum could easily get this clip off. I haven't been able to do it. It's one of the draw backs to getting old and in-flexible, I guess. I appreciate all of the suggestions, but it looks like the nuclear response is my only option.
    [SIGPIC][/SIGPIC][FONT=Comic Sans MS]'91 Shadow convertible 2.5 auto, three core RP IC, S60/.48 stg 1, ported two-piece intake/52mm TB, Menegon +1 swirl, 88 turbo cam, Venolias, Crower rods, TU deep sump pan, ported exhaust, 3" from SV to TP, Hughes TC, Peloquin diff, DSS L5 driveshafts, Shelgame cal, Koni struts/shocks. [/FONT]

  19. #19
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    Re: Have to remove two-piece upper plenum

    Quote Originally Posted by cordes View Post
    It's amazing how quickly you can get stuff done after doing it a couple of times.
    Tru' dat... I find it's something like double "book time" the 1st time, book time the second, and half book time after that.
    DD1: '02 T&C Ltd, 3.8 AWD. DD2: '15 Versa Note SV, replacing.. DDx: '14 Versa Note SV << freshly killded :( ....... Projects: '88 Voyager 3.0, Auto with shift kit, timing advance, walker sound FX muffler on 15" pumpers wrapped in 215/65/R15 H rated Nexens.... and a '95 phord escort wagon PnP head << Both may need to go :( ..... I like 3.0s ... so??? ... stop looking at me like I've got two heads!

  20. #20

    Re: Have to remove two-piece upper plenum

    Quote Originally Posted by John B View Post
    I'm removing the actuator because the diaphragm melted in an engine fire. I can't get the "e" clip out without removing the head to get at it. All the grief I've gone through trying to avoid pulling the head has been more work already than pulling the head, so to heck with it. Off it comes. I have a new set of ARP studs to put in anyway.
    Well that may be the reason it's hard to remove, could be fused or something. And it sounds like you have purpose so everything works out! Try and find one of those clips, they will be a life saver in the future.
    [SIZE="3"] [B]Jon Trotter[/B][/SIZE] [B]1985[/B] Dodge Shelby Charger, Currently decommissioned [B]1987[/B] Shelby GLHS, #937 [B]1987[/B] Shelby Lancer, #628 [QUOTE=Reeves;587010]I can be ready. Please send pics of wife. _____DodgeZ add comments here______[/QUOTE]

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