PI Intake swap tutorial. Should I make one as I do the swap? - TCCoA Forums
 
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post #1 of 13 (permalink) Old 02-22-2004, 07:16 PM Thread Starter
 
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PI Intake swap tutorial. Should I make one as I do the swap?

I've ordered the parts to do the PI intake to NPI engine swap on my bird. When the parts get here and I get a weekend with decent weather, I'm going to jump into doing this swap. The reason I went with the PI intake as opposed to the updated NPI intake is because Ford saw fit to jack the price of the updated NPI manifold to almost $600 and the PI intake was the cheapest alternative that still had the aluminum coolant crossover.

Anyway, I have a nice Fuji digital camera, plenty of memory for it and a willingness to help so... Is this something that everyone would like to have?
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post #2 of 13 (permalink) Old 02-22-2004, 10:11 PM
 
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I would like to see it done, and a parts list too
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post #3 of 13 (permalink) Old 02-22-2004, 10:16 PM
 
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ill second that.
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post #4 of 13 (permalink) Old 02-22-2004, 10:31 PM Thread Starter
 
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Ok, I'll do a parts list complete with parts numbers and a photographic essay of the swap. Now I just have to find a place that rents or sells in/lbs torque wrenches at a reasonable price.
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post #5 of 13 (permalink) Old 02-23-2004, 12:42 PM
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Let me know if you want any help Warped. I've down the swap and technically I've done it twice since I just took the intake back off this weekend to reseal it (thought i might have had a small leak).

Only took me 2 hours this past weekend.

I didn't use instructions either time. Just a print out of the torque sequence is all i needed.

I have a few pics, and can take a few more to illustrate some parts.

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http://www.nsnmotorsports.com
"Fordless" - But I do have alot of Mercon V laying around...
'96 Eagle Talon ESI

Parts ---> Dan Newman - Town & Country Ford - 800-847-2047
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post #6 of 13 (permalink) Old 02-23-2004, 02:19 PM Thread Starter
 
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Cool thanks Chrisnack. I have the torque sequence from a picture off of modulardepot.com.
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post #7 of 13 (permalink) Old 02-23-2004, 02:40 PM
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Quote:
Originally posted by Warped
Cool thanks Chrisnack. I have the torque sequence from a picture off of modulardepot.com.
I have it from my ford service cd

NSN Motorsports
http://www.nsnmotorsports.com
"Fordless" - But I do have alot of Mercon V laying around...
'96 Eagle Talon ESI

Parts ---> Dan Newman - Town & Country Ford - 800-847-2047
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post #8 of 13 (permalink) Old 02-24-2004, 10:42 PM
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i also have a full parts list and part numbers if you guys want any help. i should be doing this swap soon. just waiting for some decent weather, hast been past 40 degree's here yet.

Frank

2007 Dodge Ram 1500
2008 Suzuki GSX-R1000

Previous Rides:
2003 Suzuki GSX-R750
2003 Mustang Cobra 10th Anniversary - 11.2 @ 130
1997 Thunderbird LX 4.6 - 13.7 @ 103
1993 Thunderbird LX 3.8 - Slow
1990 Thunderbird 3.8 - Slower
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post #9 of 13 (permalink) Old 02-24-2004, 11:01 PM
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Quote:
Originally posted by fdawg97lx
hast been past 40 degree's here yet.

Frank
So?

NSN Motorsports
http://www.nsnmotorsports.com
"Fordless" - But I do have alot of Mercon V laying around...
'96 Eagle Talon ESI

Parts ---> Dan Newman - Town & Country Ford - 800-847-2047
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post #10 of 13 (permalink) Old 02-24-2004, 11:16 PM
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Quote:
Originally posted by chrisnack


So?
Yea, i'll probably put the cams and intake in next time its 40 degree's. i cant wait.

Frank

2007 Dodge Ram 1500
2008 Suzuki GSX-R1000

Previous Rides:
2003 Suzuki GSX-R750
2003 Mustang Cobra 10th Anniversary - 11.2 @ 130
1997 Thunderbird LX 4.6 - 13.7 @ 103
1993 Thunderbird LX 3.8 - Slow
1990 Thunderbird 3.8 - Slower
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post #11 of 13 (permalink) Old 03-06-2004, 06:38 PM Thread Starter
 
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*** Update! ***

I've gathered all of the necessary parts, tools and information to do the PI intake swap and will be doing it tomorrow. Wish me luck!
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post #12 of 13 (permalink) Old 04-15-2004, 12:56 AM
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any news on this yet?
all my pi intake parts are sitting in my house.....

My daily job is to fry rice for my customers....

My Bird is the nicest looking in Midland, Michigan

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post #13 of 13 (permalink) Old 04-15-2004, 01:24 AM
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Quote:
Originally posted by chuacw
any news on this yet?
all my pi intake parts are sitting in my house.....
get to swapping then. its really easy.

first drain the coolant out of the car. remove the stock manifold as complete as you can. what i mean is leave everything that you can on it ( this will make it easier when you are swapping the stuff to the new manifold). just disconect all the electrical connections and vaccum lines. if you lable them it will make it easier to rememeber where they go. Now just unbolt the manifold and take it off the car. do all the swapping of parts while its off the car, it makes it much easier than trying to do it while the manifold is on the car. once you have everything swapped over to the pi intake put that aside for now.

while the intake is off, unbolt and disconnect the coolant hard line in the valley and remove it. take off the water pump and bang out the old water pump nipple with brass hammer. install the new water pump nipple and then reinstall the water pump with a new o-ring. then install the new pi hardline and bolt it to the back of the driverside head. this is where you will need to do some fabricating. since the stock coolant hardline exits the valley at the rear of the passenger side head and connects to the heater core hose and the new pi coolant hardline exits the valley at the rear of the drivers side head you will have to find a way to connect the new hard line to the hose that runs to the heater core. this was extremely simple. buy a 90 degree elbow at autozone (or any auto parts store), 2 feet of 5/8" heater hose and some hose clamps. stick the 90 degree elbow in the hose that runs to the heater core and clamp it down. now take the 2 feet of 5/8" heater hose and connect the other end of the 90 degree elbow to the hardline and clamp both ends of the hose and your all set.

now install the pi intake. dont forget to use rtv on the intake side of the gasket, not the head side. Connect all the electrical connectors and vaccum lines. put some coolant in the car and you should be all set.

tips:

-make sure you use rtv on the intake gaskets
-make sure you use a soft hammer to bang the water pump nipple out or it will mushroom and become a real pita to get out. bang it toward the front of the car
-take off the alternator. it will give you much more room to work
-get the aluminum crossover drilled and tapped before you start

i know its not as throrough as you'd like but this swap is much easier than it seems. should only take a few hours to complete. anymore questions post them up.

Frank

2007 Dodge Ram 1500
2008 Suzuki GSX-R1000

Previous Rides:
2003 Suzuki GSX-R750
2003 Mustang Cobra 10th Anniversary - 11.2 @ 130
1997 Thunderbird LX 4.6 - 13.7 @ 103
1993 Thunderbird LX 3.8 - Slow
1990 Thunderbird 3.8 - Slower
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