Has anyone had any problems installing the Copper ISO Upgrade for an MD 5/16ths spacer? I ran into a few problems which ultimately prevented me from getting it done.

First, the coolant lines barely fit over the copper tubes, and I couldn't get the spring clips to go over the nipples at all. This was relatively minor, and wouldn't have prevented the install. Second, when I tried to align the copper unit with the plenum, or at least get it flush with the plenum inlet, the coolant line that goes behind the engine was stretched taut. Again, not a deal breaker, but certainly not optimal.

The deal breaker was that I couldn't get the copper ISO unit flush with the plenum inlet and get the holes aligned. The down-tube on the copper unit was running smack into the PCV valve and hose from the right side valve cover. The original plenum down-tube is both shorter and slightly farther back than the copper tube, so this wasn't an issue with the stock setup. The only fixes I can see are either shortening the down-tube and losing the nipple, or bending the tube slightly back and possibly running into the original plenum down-tube.

I'm probably going to take off the upper plenum again and see if I can do this again, but I was at it for a while last night and just can't get it to fit.

Any ideas out there?

 

Hi BuckeyeInMI,

What I have found with the OEM hoses is that sometimes a 5/16" hose is used while most of the time a 3/8" hose is used.

The Copper throttle body heater uses a 3/8" tube to insure it will also fit the 5/16" hose. With the smaller diameter stock hose, the fit is tight, but it always goes on. Rubbing the tube with a little liquid soap can help.

When installing the Copper plate, it is necessary to have the upper plenum removed from the lower plenum. It makes installation much easier.

I've tried to install the Copper plate when the plenum was already installed on the lower plenum (once) but it was much more difficult. I ended up just taking the upper plenum off to install the copper.

The copper tube pointing downward should be just that. Pointing downward and parallel with the stock plenum tube. It should fit. If it doesn't, that part may have been fabricated wrong or may have been bent in shipping in shipping.

It should be easy to bend the copper tube slightly to point back down. Otherwise, I can send you a replacement.

Just let me know what you would like to do.

Tony

 

Hey Tony,

The copper down-tube does face down, so I don't think it was damaged in shipping. The coolant lines do fit on the tubes (I knew the soap trick), and as snug as they are, I probably don't need the spring clips. I was thinking about removing the upper plenum just so I could get the copper ISO "prepped", but I'm still concerned about it hitting the PCV valve/hose. I'll work on it again either tonight or tomorrow and let you know how things go. It was late yesterday when I got to that part of the install, so I probably wasn't as patient as I normally am.

BTW, the spacer went in just fine. And the difference was noticeable today even though I drove to work through 9-12" of new snow.

Thanks for the tips.

 

The copper tube facing down should be completely parallel with the galvanized steel tube on the plenum. There should be enough clearance that it will clear everything else without interference.

And definitely use the hose clamps. They must be installed to insure the hoses stays in place. You never want to risk coolant hoses coming off while driving.

EDIT: It will be a lot easier to install the copper with the upper plenum removed. And be sure to unplug the battery before starting and also handle the throttle body with care. Its very sensitive to handling.

 

Well, I got up real early this morning and decided to give it another try. With your suggestions, and a few tips from Tollboothwilley, I was able to get it installed. And you were right, it was much easier to get the coolant lines attached before I put the upper plenum back on. The spring clips were a real pain, but they do eventually go into place. I honestly don't know how you could get those on if the plenum was in the way. The down-tube/coolant line is right up against the PCV valve/hose, but it will be fine.

Thanks for your help.