I went to do the install last night...

Everything went swimmingly until....

I went to do the final tightening of the plenum support bolt that goes through the throttle bdy and the bracket. I didn't make it very tight but it still stripped out the threads in the plenum. It's very soft aluminum and RSS should have re-inforced the threads at the factory like the factory one. Other than that the piece is a work of art and I hope it lives up to expectations.....

Those of you who think the factory bolts don't fit may have stripped out or damaged the threads.

So at 7:00pm I ran out to pepboys and had to buy a tapping kit for the threads. I didn't have the correct size at home, so there was an extra $35 bucks and a few rolaids. I've tapped things before but not in a few years, so I was a little nervous.

Since I spent so much time muscling in the plenum between the rubber hoses (I advise a hose pick not a screwdriver) and I didn't want to remove it again unless I really had to , I masked with painters-tape the plenum intake so metal wont get in the engine.

I also covered everything else with plastic sheets so that metal flakes won't get into the alternator and tapped out the hole and inserted in a thread coil.

The guy at the counter advised since it's aluminum threads on most of the bolts, that I should use anti-sieze on the bolts. So to be safe I did and then put it back together.

I debated tapping and coiling all four, but since those seemed OK for now I decided to leave them. My guess is that one hole the bolt was pulled forward or slightly off by the bracket and the threads got damaged until they stripped. I'm guessing the other holes only having the throttle body inbetween should be ok.

I havn't started it yet because I need to put my rear bumper cover on. I had my bumerette wetsanded and re-cleared to take out some scratches from my son's scooter leaning on it.

I will disconnect the battery today also to reset everything before I start it tomorrow.

 

Does this apply to all models? It felt like the upper right on mine was not cinching down as tight as the others...

 

I would expect since they are made out of soft aluminum

 

I wouldn't do anything to it. Let Greg know - maybe he will send you a new one.

 

Too late for me... Plus I actually feel more confident with a steel insert for the threads anyway in the problematic hole. I'm actually starting to concider doing the others.

 

Didn't encounter any of the issues detailed above, all went like clockwork.
Hope all works out for you.

On a side note there's no need to disconnect your battery like others may have mentioned?

 

Interesting, I thought the disconnection of the battery was required for the computer to relearn. Also I have read that disconnecting the battery causes you to have to reset Car stereo and reset power windows to relearn. Is this true or not?

thanks

David

 

I have a 2003, so it's MOST bus so no radio code for my PCM when you disconnect the battery. In 2002 and earlier you will need you put in your radio code.

Since it only takes a minute to disconnect why not reset everything...