Jonny Retrofit Posted January 7 Posted January 7 In order to create space in the engine bay for the Classic Retrofit AC blower unit, the original fresh air inlet plenum needs to be modified. The right-hand drive version is shown in the images below, the left-hand drive version and modification process is symmetrically opposite. 1. Remove the air inlet grille on top of the fender. Undo the screws to remove the air inlet plenum from the vehicle. You may also need to remove the bracket fixing the wheel arch to the fender. 2. Using the cutting template provided, mark the cut line on the plenum. 3. Cut the Plenum on the cut line (a circular cutting disk works well), and clean the edge up with sandpaper or similar on a flat surface to make the cut edge co-planar. 4. Fit the new metal end cap with it's tab's clipping over the plenum. Adjust the angle of the tabs with an adjustable spanner to match the plenum surface if required. Whilst pushing the end cap and plenum together to compress the sealing foam gasket, drill 2.5mm holes into the plastic plenum through the holes in the end cap tab. Fix the end cap to the plenum with the 4mm screws provided. 5. Reassemble the plenum onto the vehicle under the front fender.
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