well i have several coolant leaks coming from my well designed NPI intake manifold so its right about that time for a change. so i have a 2002 intake manifold all the parts involved but the only thing im missing is the tapped hole for the extra sensor. does anyone know how to do this correctly?

also i plan on doing this swap myself and wanted to know if anyone has done it and the difficulty level on it. im pretty handy but my only concern was the water pump nipple change and the rtv use. i kinda unsure about the exact locations your supposed to use it. i know that the channels are boot shaped on the npi heads and on the PI intake manifold they are square. that much i get but do i use it anywhere else. and does anyone else have any helpful hints?

 

http://sn95forums.com/index.php/topic,1292.0.html

this is a link to the whole swap but this site is helpful with any mod to these cars.

 

You can swap the PI intake over onto the NPI heads. There is some gain to be had,.. but nothing that you'll feel by the seat of your pants. It will be like putting a TB on. Nothing more. I have a NPI intake you can have for $50. Its in perfect condition and no leaks. It came off my 96 GT when I did my PI head swap. It will not require any modification as what you'll need to do to get the PI intake on. If your short on cash,.. I'm open for trades. Tools, parts,.. anything. I understand how difficult times are and I'm flexible. Hell I've had the thing for so long,.. I might just give it away.


Anyway,..
Before you begin the swap,.. you will need to make sure you have a few things.

1: You will need the PI coolant tube that runs through the valley. The NPI tube will be in the way of the larger PI intake. Its held on to the water pump with a small piece of rubber tubing and 2 small clamps.

2: You will need a PI thermostat neck and gasket. Your stock neck will not fit on the PI intake.

3: You will need a PI alternator and PI bracket. OR,.. you will need to drill your stock bracket to modify it to work with the PI intake.

4: You will need an intake with an aluminum cross over. You will need to drill and tap the boss just behind the thermostat neck to insert your main temp sensor. 2v engines use 2 sensors. One for the ECM and the other for your gauge cluster. The PI engines only use one on the cross over tube. The other is located by the side of the block. I have the tapping dye if you need to borrow it. Else if you dont have one I think I paid $36 for the kit at Jim and Slims tool supply if you want to buy a kit to have.

5: You will need either the conversion plate thats made to install PI intakes onto NPI heads,.. will require both,.. the NPI intake gasket and the PI intake gasket. Or,.. you will need either gasket and a considerable amount of RTV. The port shapes do not match,.. and with out the adapter plate,.. the transition from PI to NPI will more then likely negate any performance potential because of the miss match in air flow. (This is my theory and not proven). It will physically bolt on with out any modifications,.. its just the difference in port shapes that will cause concern.

Other then that,.. everything else is R&R.

If your close to NPR area I dont mind coming over and giving you a hand. We could knock it out in a couple hours time. Personally,.. I would not use the PI intake until you are ready to do the full PI head swap.

Hurst