Ok folks, with summer almost upon us it's time to prepare against overheating by getting a plenum pull done. Preventative maintenance is always better and cheaper than waiting for problems to occur. If you haven't had a plenum pull done before and/or don't know your zed's full service history, then this is a great way to consolidate at least ten of the standard maintenance jobs required in one go. This is tremendously cheaper than tackling them all individually and ranks up there just as important as the 100K service. For those who don't know me, I am happy for the owner to watch/assist the work to be done (which helps you get to know your zed better and can reduce total labour cost). Why do a Plenum Pull? Replace (or bypass) at least 10 under-plenum water hoses will will eventually leak Replace all rubber hoses from PCV and IACV systems which become hard and brittle over age and crack causing vacuum leaks Tighten and inspect all inaccessible engine bay turbo plumbing clamps ensuring no boost leaks. Many of my customers report picking up an average 1-2 PSI free boost increase just from fixing these leaks caused by loose clamps. Every plenum job I've done has found at least one loose turbo intake clamp Identify causes of poor idle, hesitation, misfires, high fuel consumption Access the fuel injectors for ultrasonic cleaning, leak test and flow testing Renew at least ten dodgy wiring / plugs to injectors/Idle units Overhaul the IACV unit (controls idle) What jobs are included? Plenum 'pull and push' Soldering ten new (injectors / CTS / AAC / FIDC and Air Regulator) wiring plugs onto wiring loom Inspect/Tighten/Replace and refit exhaust and intake valve covers Fit new crankcase breather hoses, PCV's and gaskets Under-Plenum water hoses bypassed (eliminating at least 10 unneccessary water hoses and 20 clamps from leaking in the future) Inspect/Replace Turbo water hoses Seven+ EFI fuel hoses replaced Inspect/Consolidate/Clean up AIV, PRVR and EGR system piping/solenoids/wiring etc Inspect/Pre and Post-turbo piping and tighten all screw clamps Inspect/Replace all vacuum hoses Throttle bodies/Butterflys/linkages cleaned/checked/adjusted Idle control units bench tested & reconditioned : IACV (idle control unit) / FIDC (fast idle stepper) / Air Regulator (for cold starts) Six injectors overhauled (flow tested, leak tested and ultrasonic cleaning. Including new O'rings) Plenum degreased & detailed, all superfluous underside hard pipes removed for a cleaner look (and if desired, spray painted in heat resistant enamel) Valve covers tightened / gaskets replaced / cleaned and detailed (if required) Full final tune up including datascan and consult diagnostics, idle adjustment, TPS, solenoid tests + drive test, etc etc and a hundred other 'little things' I can't think of right now Free inspection approx 1-2 weeks after to recheck everything : New fuel and water hoses do shrink over time requiring clamps to be retensioned Computer diagnostic checkup Free additional checkup in 2-3 months. Ongoing after-sales service. All work is 100% satisfaction guaranteed. How long does it take? Approx 1 - 1.5 days (up to 16-20hours max). If desired, you are welcome to observe and/or assist in part or all the work so you get to see all the jobs done for yourself. What parts are required? I recommend taking the opportunity whilst the plenum is off to replace many other top-of-engine parts that are accessible whilst the plenum is off. Much of this is preventative maitenance but is a much better approach than re-active maitenance (waiting for a part to fail). You can just get the bare minimum parts replaced or get everything done depending on your requirements. The full list of parts normally changed is here. Costs Parts: approx $450 (bare minimum) to approx $550 (standard) dependant on your requirements and current exchange rate. Both options always include all mandatory factory parts, wiring plugs, fuel and water hose etc Injector servicing: Onsite performed by Electronic Injector Services- $150 Labour: Average = $550+GST Extended = $600+GST *Capped* There are cheaper options for emergency coolant bypass jobs but not really recommended. Contact me for bookings or questions by: reply to this thread email PM me here SMS 0402 279373 (I don't always answer my mobile immediately so please leave a voicemail or SMS message) I'll have all the required parts in stock now so it's just a drive-in - drive out job. More info at www.zedcare.com
Well, I've had several intra/interstate zedders travel up to Brisbane for the plenum pull. Why not make a holiday out of it?:zlove:
Have just received latest batch of parts from Coz so have several complete plenum pull kits here on the shelf. They were earmarked for several PP & P's booked for next month but will probably have to re-order more parts by then again anyway. These are fairly cost heavy inventory so if anyone wanting an urgent job I can now do almost straight away at the moment.:zlove: PS: Have seen a lot of dialogue lately regarding removing the EGR whilst doing the plenum. There is no doubt that a leaking EGR can hurt the engine but I really recommend not removing the entire EGR & associated pipes. The extra work and hassle combined with the even worse scenario of having to refit everything if the car is defected, should be enough to discourage this. To refit the EGR & all pipes and reconnect to the exhaust requires the plenum to come off again and most likely some exhaust work. With the plenum off, it is relatively easy to check if the EGR is defective and ifso, can be temporarily bypassed if required until you have a supplementary reason to pull the gearbox (clutch etc) and/or engine when you can then replace the EGR with a 2nd hand spare or new with relative ease. The bypass is 100% reversible, requires no welding at the exhaust pipe or additional materials, and can be fitted in at time of plenum pull in just a few minutes. To remove the bypass would take approx 30 mins or less on a cold engine.:zlove: Of course if you were building an off road monster, then flick the EGR along with lots of other crap!!!
