75ZT Community

Today I revisited the plenum check, I did this because of the theft of the photo's from the original thread by PB via (Tinypic) whom they closed down when they purchased the site.


Therefore below is the revised version.

Tools I used for the plenum check. fig 1
1

Pop the bonnet fig 2/3
2

3

Bonnet open fig 4
4

Top scuttle panel needs to be removed. fig 5
5

First peel back the rubber seal fig 6
6

From the end pull the rubber off the edge holding the scuttle to the bulk head. fig 7/8/9
7

Pull it along as far as the first wiper. fig 8/9
8

9

Top cover can now be removed fig 10
10

Press in the little tags so it cover pops up 11/12
11

12

Push in the centre of the cover and it will lift free fig 13/14
13

14

Set it to one side safe.
15

This will give you access to the small front rivet clip fig 16
16

Use the small posi drive to use screw the plastic rivet clip fig 17
17

Remove this & put safe with the cover fig 18/19
18

19

Next you need to remove the scuttle clips fig 20
20

It up to you what you use the hook tool or small flat screw driver fig 21/22
21

22

There is a little hole to fit the tool into to pry the clip up fig 23
23

Which ever you use make sure you put a finger over the clip when prying upwards otherwise they can and will fly off never to be seen again. fig 24/25
24

25

Remove the first three carefully fig 26/27
26

27

Put them safe with the cover & rivet fig 28
28

The scuttle can now be lifted at the front fig 29
29

This allows you to get hold of the plenum tray fig 30
30

Pull the tray towards you with a wiggle effect fig 31
31

It will come out and free fig 32
32

Put the plenum tray safe fig 33
33

This now gives you access to the lower plenum area which also holds the ECM & pollen filter fig 34
34

You can use the torch out of the set of tools to do a quick check for water fig 35
35

To do a real check & clean out you need to remove the ECM grab hold of it & pull upwards fig 36
36

It will lift off it's bracket inside the plenum fig 37
37

Lift out & lay it on the top of the scuttle panel fig 38
38

You can now see the plenum tube & plenum floor fig 39/40
39

40

Using the tool of your choice I used a Nano plenum rod fig 41
41

Rod the plenum tube of it's debris fig 42
42

Make sure the rod exits the plenum under the car fig 43
43

After you have rodded all the debris out & cleaned the plenum floor you can replace the ECM, note the two guides on the rear of the case fig 44
44

The guides will match up to and slide into the bracket on the fire wall inside the plenum fig 45
45

Make sure the ECM is seated fully down on the bracket fig 46
46

Time now to replace the plenum tray lift the scuttle panel slightly fig 47
47

Feed in the tray fig 48
48

Push it fully home fig 49/50
49

50

re-fit the scuttle clip x3 fig 51/
51

make sure they a pushed home fully fig 52/53
52

53

With three clip in place you can move onto the front rivet. fig 54
54

Add the front rivet fig 55/56
55

56

Push in the rivet screw fully home fig 57/58
57

58

The tray is now secure fig 59
59

Now fit the rubber seal fig 60/61/62
60

61

62

Hopefully you will have added the spyhole mod to you plenum tray fig 63/64
63

64

This spyhole in then used from thereon to rod the plenums fig 65/66
65

66

Again making sure the exits fully under the car fig 67
67

Finally fit the rubber grommet fig 68
68

Fit the top scuttle cover fig 69/70
69

70

Push in the clips so not to break them fig 71
71

72

There is another lower plenum tube under the servo this is only reachable and serviced from under the car, except for the 1.8 engine which you are able to reach from in the engine bay.

Hopefully this helps new & old members and gives a full how to of the plenum clearance after the PB (Tinypic) debarcle cheers Arctic.

Great job Steve.

As we know we also have two inner wing drain tubes on our cars NS & OS, these can and will get blocked also if not serviced by rodding or protected by some sponge.

The inner drain tube fig 1
1

Use a rod to clear any debris in the tube. fig 2
2

Push the rod in & out a few times making sure it go's in as far as possible.
3

The ideal thing to do is remove the tube using a pair of long nosed pliers. fig 4/5/6
4

5

6

Once removed if the drain tube as any flaps cut them off.
7

Mine did not have any flap so was ok.
8

Clean inside the inner wing with a rag fig 9
9

Once cleaned you can re-insert the tube. fig 10/11
10

11

Push the tube fully home making sure it's sealed all round. fig 12/13
12

13

With the drain tube flap cut off and inner wing area cleaned, add some fish tank filter to stop future debris. fig 14
14

You need to filters one small and one longer fit the small one first. fig 15
15

Fit longer over the drain tube it's self fig 16/17
16

17

Do both OS & NS inner wings the same fig 18/19
18

19

These are what the earlier type inner wing drain tubes look like before the face lift. fig 20
20

Cut the end flaps off fig 21/22
21

22

Rod them out and re-fit to your car. fig 23/24/25
23

24

25

If you do not have one on the NS wing area. then add one from a scrap car

This job should also be done after any trees near your car have finished shedding their seeds. I find the plenum chamber has a nice collection from my neighbour's tree that seems to be constantly shedding one thing or another.