1996 Mustang GT Donor car
PI Intake Swap
Parts:
PI Intake Manifold(1999-2004 Mustang GT)
PI Intake Manifold Gaskets
NPI Intake Manifold Gaskets
PI-NPI Intake Manifold Adapter Plates
Coolant Block Valley Pipe
Water Nipple for Updated Coolant Pipe
Water Pump O-Ring
Thermostat Housing O-Ring
Tools:
1/4 Socket Wrench
1/2 Socket Wrench
3/4 Socket Wrench
10 MM Short and Deep Socket, Combo Wrench(Ratchetable if available)
12 MM Short and Deep Socket
13 MM Short Socket or Combo Wrench(Ratchetable if Available)
Flat Head Screw Driver
Adjustable Wrench
Quick Disconnect tool set for Fuel line Removal
Pry Bar
Heavy Duty Hammer
Pliers for hose clamps
Procedure:
0.) Drain all of the coolant from the radiator and disconnect the negative battery cable
1.) Disconnect Every Single Electrical Wiring Harness connector you can find on and around your intake manifold.
2.) Remove the Strut Tower Brace there are 8 Bolts
3.) Remove the Air Intake Tubing by releasing the Airbox separator and loosening the hose clamp at the throttle body, there are 2 electrical connectors and 2 Vacuum hoses to remove here
4.) Remove all Spark Plug wires from the plug and move them to the side**optional but helpful
5.) Remove the Purge Valve Solenoid (10 MM) on the Plenum Bracket in order to remove the steel line connected to the EGR(adjustable Wrench) without damaging it. There is one electrical connector along with one paired Vacuum line here in addition to the steel EGR line
6.) Proceed to the plenum and Throttle body, there are 5 10 MM bolts along with a few vacuum lines and 2 electrical connectors, throttle return spring, throttle cable and the 10 MM bolt holding the cable, move all cables and vacuum hoses out of the way to avoid damaging them
7.) Remove the serpentine belt from the Alternator by using the 3/4 Socket wrench to release the tension, then remove the alternator and disconnect the two clips holding the ignition wires from the bracket***be very careful not to leave your hands behind the wrench because it will go back with extreme force and can break a finger or two by jamming it against the coil packs.
8.) Use the special tools to disconnect the 2 fuel lines and remove the 4 studs to pull the rail out with the injectors***be sure to pull the injectors from the manifold one by one and not to remove them from the rail because you will need to replace the O-Rings if you do
9.) Remove the Thermostat Housing along with all of the intake manifold bolts, then remove any coolant hoses from the back of the manifold and pull it off gently.
10.) Remove the hose from the top of the coolant tube that runs in the block valley. There are 2 bolts on the back of the bracket for this tube, be patient this is the hardest part of the job, then you are ready to remove the clamps from the hose at the inside of the block. ****NOTE if you do not have the new nipple do not cut the pipe in order to skip replacing the nipple, the intake will not clear the old nipple by itself you need to replace it, and if you cut the new pipe you will ruin it because it presses over the new nipple and you can not afford to cut it.
11.) Remove the 4 bolts holding the water pump on the block, then remove the pump.****this is tricky, replace the pulley on the shaft and hammer the pump from side to side so it will move, then use a pry bar using the pulley for leverage and it should come out.
12.) Get a broad object to place in front of the nipple in the valley to not damage it too much, and hammer it through to the front and replace it with the new PI Nipple by hammering it through from the front to the rear.
13.) Replace the O-Ring on the water pump and replace it.
14.) Place the new water tube in the valley and use only one bolt for the bracket and the new end does not take any hose or clamps just push it over the o-rings.
15.) Clean all of the ports and gasket mounting area for the gaskets, I recommend that you use an air hose to blow out any dust that may have fallen in the ports and dry any coolant that may have spilled in there as well
16.) Place the NPI gaskets in place using the guide pins, then put the adapter plates, break all of the guide pins off of the PI gaskets if your plates do not have holes to support them.
17.) Depending on what intake your car had before this may vary. If your original intake has the updated aluminum coolant crossover unbolt it from your old manifold and place it on your PI manifold to save some retrofitting. Just clean it up and use silicone or new gaskets to avoid leaks
17.
If you have the old NPI intake with a plastic coolant crossover you have a few options, you may be able to buy the aluminum piece through Ford or a junkyard. Or you can buy a T Fitting to put the 2 coolant sensors on rather than tapping the new crossover. PI intakes only have a hole for one coolant sensor and NPI engines have 2 sensors, it’s your choice.18.) Now you can place your PI intake Manifold on the engine and line it up to bold it on from inside out to avoid cracking it.
19.) from here on you can just reverse the applicable steps from #9 Back and double check everything once you are done and check for leaks immediately and keep an eye on your coolant for the first few days
__________________