wills said:

GTI - Have you not already downloaded RAVE so you look this sort of info up in the workshop manual??

-Wills

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gti power said:

can anyone help i have goto stip my intake manifold off my p reg 4.0v8 to drill and tap manifold for lpg conversion.
i removed the x6 allen bolts on the plenum and various pipes etc, under the plenum cover i found 8 upright flutes and x6 11mm bolts i removed these but found could not move the alloy housing

what is the defenition of the plenum chamber?

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classic kev said:

As far as I know, the 4.0 V8 is the same as the 3.9 in the RRC and Disco. The plenum comprises plenum chamber upper (top cover), ram pipes (or trumpets) and the plenum chamber lower (ram housing). All of this is bolted onto the inlet manifold.

It is quite easy to strip it all down. Remove the top cover, then undo the bolts on the ram housing. The ram housing may be stuck to the inlet manifold. Check you have undone all the bolts, then tap the ram housing using a rubber mallet. Don't hit the ram pipes. Avoid levering the ram housing as it is easy to damage the machined face that is in contact with the inlet manifold.

Clean the top of the inlet manifold and the bottom of the ram housing - make sure you remove all the old sealant and do not score the surfaces. If you need to clean the surfaces, it can be done by using a sanding block and 400 grit wet and dry lubricated with light oil (3 in 1 or WD40). Do this carefully and do not apply more than light pressure. This should resurface both parts, but do not do this if you are not confident/sure about what you are doing. Hope I'm not telling you how to suck eggs.

Apply fresh Hylomar or similar sealant, reassemble and tighten bolts to specified torque.

Hope that helps.

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