Pi swap on 94 tbird - TCCoA Forums
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post #1 of 22 (permalink) Old 05-15-2016, 08:07 PM Thread Starter
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Pi swap on 94 tbird

My intake just cracked and need some help on doing the pi swap and on what parts i am going to need thanks!
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post #2 of 22 (permalink) Old 05-15-2016, 08:17 PM
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My intake just cracked and need some help on doing the pi swap and on what parts i am going to need thanks!
Just the intake, or the full PI swap?

There's some stickies in the technical articles. But short form, if you're doing just the intake, you need an intake, a valley tube, the correct alternator bracket, some RTV, and some time.

For the full PI Swap, you add heads to the mix, a tuner, and a tune.

It's really not so bad, I'd say go with the full swap. Get the correct head gaskets (for a PI motor), and do the whole thing.

97 Thunderbird LX (The GT Bird)
2003 Explorer WAP block with Modular Head Shop "street ported" heads and Stage 2 PI NA cams, 75mm Accufab throttle body, C&L upper intake plenum, Kooks 1.75" primary/3" collector headers, 2.5" full exhaust with mid mount Magnaflow dual in/out muffler, 24lb/hr injectors, 80mm MAF, Tuning from Don @ www.lasotaracing.com, CAI that feeds from fenderwell. Jmod, 3.73:1 TL in Mark VIII carrier, Mark VIII aluminum LCAs, 93 Mark VIII driveshaft, PBR brakes (soon to be Cobras), 18x9 wheels with 35mm offset, 255/40/ZR18 Tires, Front and Rear strut/shock bracing, GR-2 shocks, Eibach 1.5" springs, 1989 SC front and rear sway bars.
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post #3 of 22 (permalink) Old 05-15-2016, 08:35 PM
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You've piqued my curiosity; how exactly did you crack the stock 94 aluminum intake?

With that in mind you'll need what woodman mentioned and on top of that 96/7 fuel lines/rails, throttle cable, EGR tube, vacuum lines, throttle body/plenum, IAC, intake tube, PCV tubes, alternator bracket, ect, ect.
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post #4 of 22 (permalink) Old 05-15-2016, 09:48 PM Thread Starter
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Originally Posted by XR7-4.6 View Post
You've piqued my curiosity; how exactly did you crack the stock 94 aluminum intake?

With that in mind you'll need what woodman mentioned and on top of that 96/7 fuel lines/rails, throttle cable, EGR tube, vacuum lines, throttle body/plenum, IAC, intake tube, PCV tubes, alternator bracket, ect, ect.
Well the car was sitting for 16 years in the heat and cold so it might of gotten brittle and just broke ive been driving it for about three months

Zak Garcia
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post #5 of 22 (permalink) Old 05-15-2016, 09:50 PM Thread Starter
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I just picked up a pi intake from a mustang for 35 bucks and im only doing the intake I don't have enough cash/time to do the whole swap

Zak Garcia
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post #6 of 22 (permalink) Old 05-15-2016, 09:53 PM
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Originally Posted by XR7-4.6 View Post
You've piqued my curiosity; how exactly did you crack the stock 94 aluminum intake?

With that in mind you'll need what woodman mentioned and on top of that 96/7 fuel lines/rails, throttle cable, EGR tube, vacuum lines, throttle body/plenum, IAC, intake tube, PCV tubes, alternator bracket, ect, ect.
I keep forgetting I'm spoiled with my 97, it had all that stuff.

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2003 Explorer WAP block with Modular Head Shop "street ported" heads and Stage 2 PI NA cams, 75mm Accufab throttle body, C&L upper intake plenum, Kooks 1.75" primary/3" collector headers, 2.5" full exhaust with mid mount Magnaflow dual in/out muffler, 24lb/hr injectors, 80mm MAF, Tuning from Don @ www.lasotaracing.com, CAI that feeds from fenderwell. Jmod, 3.73:1 TL in Mark VIII carrier, Mark VIII aluminum LCAs, 93 Mark VIII driveshaft, PBR brakes (soon to be Cobras), 18x9 wheels with 35mm offset, 255/40/ZR18 Tires, Front and Rear strut/shock bracing, GR-2 shocks, Eibach 1.5" springs, 1989 SC front and rear sway bars.
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post #7 of 22 (permalink) Old 05-15-2016, 09:55 PM
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I just picked up a pi intake from a mustang for 35 bucks and im only doing the intake I don't have enough cash/time to do the whole swap
Then get a 99-04 Mustang GT valley tube and nipple (or one off an 02+ Crown Vic/Town Car/GrandMa, 02-05 Explorer/Mountaineer, and maybe some F-150's... Not sure about the trucks) and some RTV. You can have it done in a weekend. You need to let the RTV cure I believe.

97 Thunderbird LX (The GT Bird)
2003 Explorer WAP block with Modular Head Shop "street ported" heads and Stage 2 PI NA cams, 75mm Accufab throttle body, C&L upper intake plenum, Kooks 1.75" primary/3" collector headers, 2.5" full exhaust with mid mount Magnaflow dual in/out muffler, 24lb/hr injectors, 80mm MAF, Tuning from Don @ www.lasotaracing.com, CAI that feeds from fenderwell. Jmod, 3.73:1 TL in Mark VIII carrier, Mark VIII aluminum LCAs, 93 Mark VIII driveshaft, PBR brakes (soon to be Cobras), 18x9 wheels with 35mm offset, 255/40/ZR18 Tires, Front and Rear strut/shock bracing, GR-2 shocks, Eibach 1.5" springs, 1989 SC front and rear sway bars.
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post #8 of 22 (permalink) Old 05-16-2016, 08:16 AM
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Originally Posted by Slow94lx View Post
I just picked up a pi intake from a mustang for 35 bucks and im only doing the intake I don't have enough cash/time to do the whole swap
That won't work. Either have to do the full swap, or nothing.

I would just buy some intake gaskets for the 94 intake and be done with it. Your leak should be either from gaskets or heater hose connection at the manifold.

If you actually cracked the intake from freeze/thaw cycles, you likely got bigger problems than an intake manifold. The only way that could happen is if there was insufficient antifreeze in the car.

Al

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post #9 of 22 (permalink) Old 05-16-2016, 10:07 AM
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That won't work. Either have to do the full swap, or nothing.

I would just buy some intake gaskets for the 94 intake and be done with it. Your leak should be either from gaskets or heater hose connection at the manifold.

If you actually cracked the intake from freeze/thaw cycles, you likely got bigger problems than an intake manifold. The only way that could happen is if there was insufficient antifreeze in the car.

Al
Why won't the manifold swap work? I've read about other folks putting the PI manifold on PI Heads, just using RTV to block a hole.

97 Thunderbird LX (The GT Bird)
2003 Explorer WAP block with Modular Head Shop "street ported" heads and Stage 2 PI NA cams, 75mm Accufab throttle body, C&L upper intake plenum, Kooks 1.75" primary/3" collector headers, 2.5" full exhaust with mid mount Magnaflow dual in/out muffler, 24lb/hr injectors, 80mm MAF, Tuning from Don @ www.lasotaracing.com, CAI that feeds from fenderwell. Jmod, 3.73:1 TL in Mark VIII carrier, Mark VIII aluminum LCAs, 93 Mark VIII driveshaft, PBR brakes (soon to be Cobras), 18x9 wheels with 35mm offset, 255/40/ZR18 Tires, Front and Rear strut/shock bracing, GR-2 shocks, Eibach 1.5" springs, 1989 SC front and rear sway bars.
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post #10 of 22 (permalink) Old 05-16-2016, 10:17 AM
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I think he's referring to the necessary 96-97 conversion parts. PI intake on npi heads is successfully done all the time, my car was that way for years.

Quote:
Originally Posted by Slow94lx View Post
Well the car was sitting for 16 years in the heat and cold so it might of gotten brittle and just broke ive been driving it for about three months
yeah, no.

It's likely the gaskets.
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post #11 of 22 (permalink) Old 05-16-2016, 12:34 PM
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Why won't the manifold swap work?
Re-read post #5. He's trying to just swap the newer style intake manifold onto a 94-95.

All that extra stuff is the reason I never did it on my 95.

Al
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post #12 of 22 (permalink) Old 05-16-2016, 05:23 PM Thread Starter
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I pulled everything off today and the heater hose from the water pump nipple was rusted. I am going to continue to do the pi intake swap.
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post #13 of 22 (permalink) Old 05-16-2016, 05:24 PM Thread Starter
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Not sure which car has the heater hose that goes to the driver side so it clears the deep valley. Also which car do I use for the fuel rail?
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post #14 of 22 (permalink) Old 05-16-2016, 06:36 PM
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Not sure which car has the heater hose that goes to the driver side so it clears the deep valley. Also which car do I use for the fuel rail?
99-04 Mustang GT, 02+ Crown Vic/GrandMa/Town Car, 02-05 Explorer/Mountaineer.

Basically, anything with a PI motor.

97 Thunderbird LX (The GT Bird)
2003 Explorer WAP block with Modular Head Shop "street ported" heads and Stage 2 PI NA cams, 75mm Accufab throttle body, C&L upper intake plenum, Kooks 1.75" primary/3" collector headers, 2.5" full exhaust with mid mount Magnaflow dual in/out muffler, 24lb/hr injectors, 80mm MAF, Tuning from Don @ www.lasotaracing.com, CAI that feeds from fenderwell. Jmod, 3.73:1 TL in Mark VIII carrier, Mark VIII aluminum LCAs, 93 Mark VIII driveshaft, PBR brakes (soon to be Cobras), 18x9 wheels with 35mm offset, 255/40/ZR18 Tires, Front and Rear strut/shock bracing, GR-2 shocks, Eibach 1.5" springs, 1989 SC front and rear sway bars.
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post #15 of 22 (permalink) Old 05-16-2016, 07:11 PM
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Fuel rail AND lines, you need from a 96/7 tbird/cougar.
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post #16 of 22 (permalink) Old 05-16-2016, 07:52 PM
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Originally Posted by XR7-4.6 View Post
Fuel rail AND lines, you need from a 96/7 tbird/cougar.
I really need to read the whole post before I reply!

97 Thunderbird LX (The GT Bird)
2003 Explorer WAP block with Modular Head Shop "street ported" heads and Stage 2 PI NA cams, 75mm Accufab throttle body, C&L upper intake plenum, Kooks 1.75" primary/3" collector headers, 2.5" full exhaust with mid mount Magnaflow dual in/out muffler, 24lb/hr injectors, 80mm MAF, Tuning from Don @ www.lasotaracing.com, CAI that feeds from fenderwell. Jmod, 3.73:1 TL in Mark VIII carrier, Mark VIII aluminum LCAs, 93 Mark VIII driveshaft, PBR brakes (soon to be Cobras), 18x9 wheels with 35mm offset, 255/40/ZR18 Tires, Front and Rear strut/shock bracing, GR-2 shocks, Eibach 1.5" springs, 1989 SC front and rear sway bars.
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post #17 of 22 (permalink) Old 05-16-2016, 08:25 PM
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Ive been wanting to do this on my 95 but the list of parts is so extensive I think I would eff something up partway through, or forget things.
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post #18 of 22 (permalink) Old 05-16-2016, 09:42 PM
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Ive been wanting to do this on my 95 but the list of parts is so extensive I think I would eff something up partway through, or forget things.
Go slow, label EVERYTHING, take pictures as you take the off, and take notes. Worth the time.
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97 Thunderbird LX (The GT Bird)
2003 Explorer WAP block with Modular Head Shop "street ported" heads and Stage 2 PI NA cams, 75mm Accufab throttle body, C&L upper intake plenum, Kooks 1.75" primary/3" collector headers, 2.5" full exhaust with mid mount Magnaflow dual in/out muffler, 24lb/hr injectors, 80mm MAF, Tuning from Don @ www.lasotaracing.com, CAI that feeds from fenderwell. Jmod, 3.73:1 TL in Mark VIII carrier, Mark VIII aluminum LCAs, 93 Mark VIII driveshaft, PBR brakes (soon to be Cobras), 18x9 wheels with 35mm offset, 255/40/ZR18 Tires, Front and Rear strut/shock bracing, GR-2 shocks, Eibach 1.5" springs, 1989 SC front and rear sway bars.
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post #19 of 22 (permalink) Old 05-17-2016, 10:43 AM Thread Starter
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So yesterday I grabbed a heater coolant hose from a cop car the goes towards the driver side to clear the intake manifold
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post #20 of 22 (permalink) Old 05-17-2016, 04:07 PM
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It was almost 2 years ago I swapped the old 94-95 style intake manifold for the 96+ variety with a Typhoon PI intake. Besides the valley hose and the water pump nipple you will also need an EGR tube either from a donor car or buy a new one for a 2003 Explorer like I did. For the fuel lines you do have the option of keeping the old ones and using fuel rails from a 94 Gran Marquis like I was forced to do because all of the junkyard cars around here are resting on their frames. You will also need access to a cruise control cable from a 96+ MN-12 but you only need the plastic end that attaches to the throttle body. I almost forgot about the passenger side coil pack bracket and the DPFE bracket on the back of the passenger side head. I can't remember for sure but I think I switched to the newer EVR that attaches to the coil pack bracket.

I had made numerous tips to the junkyard to get everything I needed and this simple swap became a lot more expensive than first expected. Soo glad I did it though! The newer intake is so much easier to deal with when messing with the EGR system and vacuum lines. The added power is nice too.

-Randy-
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post #21 of 22 (permalink) Old 05-17-2016, 04:55 PM
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99-04 Mustang GT, 02+ Crown Vic/GrandMa/Town Car, 02-05 Explorer/Mountaineer.

Basically, anything with a PI motor.
These are the ones you want to buy engines out of; they rarely get beat on.

And most are rear end collisions, for some reason.

That's where I got a PI engine, and several Transmissions.
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post #22 of 22 (permalink) Old 05-17-2016, 06:26 PM
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I did the intake swipe on my 95 over 7 years ago still no problems
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