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argh...so i figured this out after quite a few - quite a few! - removals/installations of the plenum...
when i removed the plenum the first time, i loosened the 8 clamps holding the plenum to the throttles and pulled it up...it came off easily with a pop...
when re-seating/re-installing the plenum, i finally realized that the clamps needed to be opened more - especially the back ones...once i did that, the plenum fit perfectly...
a tip - shine an led flashlight down each bank to see that the plenum fits all cylinders evenly...its easy to see the fit when you shine down each bank from the front to the back...
the codes - btw - indicated that the air/fuel ratio was not right due to the misaligned plenum...
all good now!
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