NPI to PI Intake Swap...

CMSF2003 · March 2nd, 2007, 01:11 PM

Just a note, the coolant tube nipple IS required for the 96 and 97, 98 already has the style needed to replace the tube.

I also sell the complete kit on my website custommustang

Casper98GT · March 2nd, 2007, 01:52 PM

Yes the 98 already has it and you can do the job without the nipple. I have already done 3 of them.

Pauldunlap · March 6th, 2007, 08:58 AM

I did this mod and everything was ok for about 150 miles then the check engine light came on. I could see no leaks but began to smell antifreeze. Then the light started blinking and white smoke came out of the drivers side pipe.
Any advice at this point would be appreciated. Should I buy new gaskets when I take the intake off again to find the problem? Maybe I used too much gasket maker in the trouble spot? I have had this intake on and off 3 times already because of leaks. Should I retorque the bolts after it has warmed up?

Casper98GT · March 6th, 2007, 10:06 AM

i would suggest NOT driving it. If youre blowing white smoke coolant is getting burned. Take the intake off ASAP and check it out. Something isnt lined up or youre not sealing properly.

Pauldunlap · March 6th, 2007, 10:58 AM

Thanks, I am going to take it off this afternoon after work.

Pauldunlap · March 7th, 2007, 01:37 PM

ok, I took the intake back off. The gaskets were stuck to the heads by the sealant. Everything lined up. The sealant was in the correct place. (between the gasket and the head). I couldn't see a place where it looked like there was a leak. Could the antifreeze be going over the gasket, between the intake and gasket. Should I put sealant on top of the gasket, also? I'm thinking that might fix the problem. There are only 2 places it could be leaking. The 2 problem areas. If I used too much sealant would that cause a leak? It didn't appear to be too much, but I'm not sure.
By the way my car makes noticeably more power with this intake, even in the low rpm range.

Casper98GT · March 7th, 2007, 03:01 PM

well the problem isnt the top of the gasket because its a perfect match to the intake. im not sure what else it could be. its a brand new intake right? only way for it to burn is when it doesnt seal.

Pauldunlap · March 7th, 2007, 03:26 PM

Yes, it's a new intake. I bought a kit from Florida.

Casper98GT · March 7th, 2007, 04:22 PM

when you removed the intake, can you see dry coolant, like residue anywhere, to as a poiint where its leaking?

Pauldunlap · March 7th, 2007, 04:58 PM

No dry coolant that I can detect. One thing...I checked my intake with a straight edge and the surface that mates to the heads is not straight. There is about 1/8 inch gap at the end and the high place seems to be in the middle. Both sides are like this. One not quite as bad as the other. Is this normal?

Pauldunlap · March 7th, 2007, 05:09 PM

Casper,
I went back on your hint and checked the old gaskets. The gasket from the driver's side has coolant all the way around the intake port in the back. I am wondering if I put too much RTV sealant in that spot. The sealant squished out to the outside of the intake mating surface and a little oozed into the water port.

Casper98GT · March 7th, 2007, 06:03 PM

There might be a high spot due to when you tighten it down it levels out.

And you ARE using PI gaskets right ???

And if you have coolant near the intake port, youre buring coolant. Not good. Make sure you get a good seal and tighten it down first, dont get it SUPER tight, but enough to seal. then wait a few hours and torque it. So it all doesnt spill out

Pauldunlap · March 7th, 2007, 06:30 PM

I am using the PI gaskets. They have more square port openings than the teardrop shaped NPI heads. I got them at the Ford dealership.

Pauldunlap · March 7th, 2007, 06:54 PM

I also think you make a valid point with the warp in the intake. The bolt I torque first is the highest spot.

98GEETEE · March 13th, 2007, 10:52 PM

Wow, this has got to be one of the best write up's on a Non PI to PI intake swap, great job. But i do have a question...i bought a PI intake off of ebay (at a damn good price too, $30!) off of an 01 Grand Marquis. I understand that I have two coolant sensors, and that if you have an Aluminum Crossover, you tap it, but i do not have an Aluminum Crossover. I have the plastic one, and there is no place to put the other. So if you could please let me know what to do with the other temp sensor, it would be greatly appriciated! Thanks!

Casper98GT · March 13th, 2007, 11:32 PM

yeah sell it and get a PI updated manifold. Because youre takin the chance of that one breaking as well as the NPI intakes. It wasnt even worth 30 bucks.

98GEETEE · March 14th, 2007, 03:14 PM

so i cant even just tap the plastic to make a second hole for the other sensor?

Casper98GT · March 14th, 2007, 04:24 PM

yes you can, but its plastic. Its going to lessen the durability of it even more by doing this. You can relocate the sensor to the block drain on the lower drivers side below the exhaust manifold. Its the same thread.

98GEETEE · March 15th, 2007, 03:36 PM

what about tapping the thermostat housing? will that work at all?

smasher41 · March 16th, 2007, 12:13 AM

thats how mine is done, ill post pics this weekend.

March 2nd, 2007, 01:52 PM	#42
Casper98GT Hardcore Enthusiast Join Date: Aug 2005 Location: NEW HAMPSHIRE Posts: 2,316	Yes the 98 already has it and you can do the job without the nipple. I have already done 3 of them. __________________ Ford/Toyota tech. -93 LX, X303 heads, F-cam, Trickflow u/l, 1.6 RR, FR wires, MSD cap/rotor, Elec. fan, a/c delete, smog delete, sn95 fuel rails with BBK regulator, 75mm TB and EGR, Vortech S-trim w/intercooler, 42lb inj/PMAS, 3.55's -

March 6th, 2007, 10:06 AM	#44
Casper98GT Hardcore Enthusiast Join Date: Aug 2005 Location: NEW HAMPSHIRE Posts: 2,316	i would suggest NOT driving it. If youre blowing white smoke coolant is getting burned. Take the intake off ASAP and check it out. Something isnt lined up or youre not sealing properly. __________________ Ford/Toyota tech. -93 LX, X303 heads, F-cam, Trickflow u/l, 1.6 RR, FR wires, MSD cap/rotor, Elec. fan, a/c delete, smog delete, sn95 fuel rails with BBK regulator, 75mm TB and EGR, Vortech S-trim w/intercooler, 42lb inj/PMAS, 3.55's -

March 7th, 2007, 03:01 PM	#47
Casper98GT Hardcore Enthusiast Join Date: Aug 2005 Location: NEW HAMPSHIRE Posts: 2,316	well the problem isnt the top of the gasket because its a perfect match to the intake. im not sure what else it could be. its a brand new intake right? only way for it to burn is when it doesnt seal. __________________ Ford/Toyota tech. -93 LX, X303 heads, F-cam, Trickflow u/l, 1.6 RR, FR wires, MSD cap/rotor, Elec. fan, a/c delete, smog delete, sn95 fuel rails with BBK regulator, 75mm TB and EGR, Vortech S-trim w/intercooler, 42lb inj/PMAS, 3.55's -

March 7th, 2007, 04:22 PM	#49
Casper98GT Hardcore Enthusiast Join Date: Aug 2005 Location: NEW HAMPSHIRE Posts: 2,316	when you removed the intake, can you see dry coolant, like residue anywhere, to as a poiint where its leaking? __________________ Ford/Toyota tech. -93 LX, X303 heads, F-cam, Trickflow u/l, 1.6 RR, FR wires, MSD cap/rotor, Elec. fan, a/c delete, smog delete, sn95 fuel rails with BBK regulator, 75mm TB and EGR, Vortech S-trim w/intercooler, 42lb inj/PMAS, 3.55's -

March 7th, 2007, 06:03 PM	#52
Casper98GT Hardcore Enthusiast Join Date: Aug 2005 Location: NEW HAMPSHIRE Posts: 2,316	There might be a high spot due to when you tighten it down it levels out. And you ARE using PI gaskets right ??? And if you have coolant near the intake port, youre buring coolant. Not good. Make sure you get a good seal and tighten it down first, dont get it SUPER tight, but enough to seal. then wait a few hours and torque it. So it all doesnt spill out __________________ Ford/Toyota tech. -93 LX, X303 heads, F-cam, Trickflow u/l, 1.6 RR, FR wires, MSD cap/rotor, Elec. fan, a/c delete, smog delete, sn95 fuel rails with BBK regulator, 75mm TB and EGR, Vortech S-trim w/intercooler, 42lb inj/PMAS, 3.55's -

March 2nd, 2007, 01:11 PM	#41
CMSF2003 Look Ma! My First Post! Join Date: Mar 2007 Posts: 1	Just a note, the coolant tube nipple IS required for the 96 and 97, 98 already has the style needed to replace the tube. I also sell the complete kit on my website custommustang

March 6th, 2007, 08:58 AM	#43
Pauldunlap Newbie Join Date: Feb 2007 Posts: 12	I did this mod and everything was ok for about 150 miles then the check engine light came on. I could see no leaks but began to smell antifreeze. Then the light started blinking and white smoke came out of the drivers side pipe. Any advice at this point would be appreciated. Should I buy new gaskets when I take the intake off again to find the problem? Maybe I used too much gasket maker in the trouble spot? I have had this intake on and off 3 times already because of leaks. Should I retorque the bolts after it has warmed up?

March 6th, 2007, 10:58 AM	#45
Pauldunlap Newbie Join Date: Feb 2007 Posts: 12	Thanks, I am going to take it off this afternoon after work.

March 7th, 2007, 01:37 PM	#46
Pauldunlap Newbie Join Date: Feb 2007 Posts: 12	ok, I took the intake back off. The gaskets were stuck to the heads by the sealant. Everything lined up. The sealant was in the correct place. (between the gasket and the head). I couldn't see a place where it looked like there was a leak. Could the antifreeze be going over the gasket, between the intake and gasket. Should I put sealant on top of the gasket, also? I'm thinking that might fix the problem. There are only 2 places it could be leaking. The 2 problem areas. If I used too much sealant would that cause a leak? It didn't appear to be too much, but I'm not sure. By the way my car makes noticeably more power with this intake, even in the low rpm range.

March 7th, 2007, 03:26 PM	#48
Pauldunlap Newbie Join Date: Feb 2007 Posts: 12	Yes, it's a new intake. I bought a kit from Florida.

March 7th, 2007, 04:58 PM	#50
Pauldunlap Newbie Join Date: Feb 2007 Posts: 12	No dry coolant that I can detect. One thing...I checked my intake with a straight edge and the surface that mates to the heads is not straight. There is about 1/8 inch gap at the end and the high place seems to be in the middle. Both sides are like this. One not quite as bad as the other. Is this normal?

March 7th, 2007, 05:09 PM	#51
Pauldunlap Newbie Join Date: Feb 2007 Posts: 12	Casper, I went back on your hint and checked the old gaskets. The gasket from the driver's side has coolant all the way around the intake port in the back. I am wondering if I put too much RTV sealant in that spot. The sealant squished out to the outside of the intake mating surface and a little oozed into the water port.

March 7th, 2007, 06:30 PM	#53
Pauldunlap Newbie Join Date: Feb 2007 Posts: 12	I am using the PI gaskets. They have more square port openings than the teardrop shaped NPI heads. I got them at the Ford dealership.

March 7th, 2007, 06:54 PM	#54
Pauldunlap Newbie Join Date: Feb 2007 Posts: 12	I also think you make a valid point with the warp in the intake. The bolt I torque first is the highest spot.

March 13th, 2007, 10:52 PM	#55
98GEETEE Newbie Join Date: Mar 2007 Posts: 3	Wow, this has got to be one of the best write up's on a Non PI to PI intake swap, great job. But i do have a question...i bought a PI intake off of ebay (at a damn good price too, $30!) off of an 01 Grand Marquis. I understand that I have two coolant sensors, and that if you have an Aluminum Crossover, you tap it, but i do not have an Aluminum Crossover. I have the plastic one, and there is no place to put the other. So if you could please let me know what to do with the other temp sensor, it would be greatly appriciated! Thanks!

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March 13th, 2007, 11:32 PM	#56
Casper98GT Hardcore Enthusiast Join Date: Aug 2005 Location: NEW HAMPSHIRE Posts: 2,316	yeah sell it and get a PI updated manifold. Because youre takin the chance of that one breaking as well as the NPI intakes. It wasnt even worth 30 bucks. __________________ Ford/Toyota tech. -93 LX, X303 heads, F-cam, Trickflow u/l, 1.6 RR, FR wires, MSD cap/rotor, Elec. fan, a/c delete, smog delete, sn95 fuel rails with BBK regulator, 75mm TB and EGR, Vortech S-trim w/intercooler, 42lb inj/PMAS, 3.55's -

March 14th, 2007, 03:14 PM	#57
98GEETEE Newbie Join Date: Mar 2007 Posts: 3	so i cant even just tap the plastic to make a second hole for the other sensor?

March 14th, 2007, 04:24 PM	#58
Casper98GT Hardcore Enthusiast Join Date: Aug 2005 Location: NEW HAMPSHIRE Posts: 2,316	yes you can, but its plastic. Its going to lessen the durability of it even more by doing this. You can relocate the sensor to the block drain on the lower drivers side below the exhaust manifold. Its the same thread. __________________ Ford/Toyota tech. -93 LX, X303 heads, F-cam, Trickflow u/l, 1.6 RR, FR wires, MSD cap/rotor, Elec. fan, a/c delete, smog delete, sn95 fuel rails with BBK regulator, 75mm TB and EGR, Vortech S-trim w/intercooler, 42lb inj/PMAS, 3.55's -

March 15th, 2007, 03:36 PM	#59
98GEETEE Newbie Join Date: Mar 2007 Posts: 3	what about tapping the thermostat housing? will that work at all?

March 16th, 2007, 12:13 AM	#60
smasher41 Newbie Join Date: Dec 2006 Posts: 17	thats how mine is done, ill post pics this weekend.