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.
-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.