I may be getting a Explorer Intakeand I was wondering what I will have to do to have my car running right. I heard something like all the vacuum connections arent the same and Im going to have to rig something up to work. All help is appreciated.
Thanks,
Jesse
I got mine off a 96 Explorer with the 19# injectors and 65 MM throttle body for $250.
The Explorer manifold isn't drilled for the ACT sensor. You will have to extend the ACT harness to relocate the ACT sensor to the air filter box. I went to Home Depot and found a brass fitting & some washers to secure the ACT in the airbox. I mounted the ACT up near the upper radiator hose in the stock air box.
Use the TPS and IAB from your old throttle body. All the EGR passages were there and fit OK. Use you old fuel rails and regulator. If you use the 65 mm throttle body, you will need a new EGR spacer adapter and gaskets. Without the EGR spacer, there is no place to mount the throttle linkage support bracket.
I used the stock water lines on the Explorer manifold and they connected up to the EGR without any problems. I made a “U” out of ½” copper pipe and sweat soldered it together. Then I used it and some hose with clamps to bypass the leaky heater I have. You don't need heat very often here in Central Florida...
The vacuum lines you need are 1 small line for fuel pressure regulator, 1 small line for A/C, 1 small line for EGR and another small line for the smog pump. One big line at the back goes to the vacuum tree for the power brake & A/C, the other big line goes out the front for the carbon canister. In a pinch, one of the small lines can connect to the spare port on the vacuum tree.
The stock Explorer linkage didn't come anywhere near fitting, so I made an adapter plate for the throttle linkage so I could use the 65 MM throttle body.
This is what I did:
Make a drawing of the position of the old throttle body linkage arm and its angular position relative to the centerline of the throttle body. Remove the ball stud off the explorer TB to make way for the adapter plate. Drill and tap a 10-32 hole in the linkage parallel to the TB shaft. Make an angle bracket out of 1" angle iron 3/8", drill a 3/16 hole in the center of each one of the legs. Then bolt it on where the hole was drilled & tapped. Then make a circular adapter plate out of 1/4" thick aluminum to bolt the two linkage arms together. Then bolt the aluminum plate to the existing linkage, and the angle bracket. Next mount the arm with the ball stud off the old throttle body on the adapter plate using the drawing to get the angle correct. You will need an aircraft type countersink for one of the bolts that secures the plate to the explorer linkage arm. It ends up being under the arm with the ball stud for the linkage. It works great and looks neat.
A trip to the welding shop with the explorer TB and the arm from your old Mustang TB would probably accomplish the same thing. I didn't have access to a welder, so I fabb'ed the plate in my shop. I took about 1.5 hours to do it, it was a measure, cut, and fit type of operation.
I got mine off a 96 Explorer with the 19# injectors and 65 MM throttle body for $250.
The Explorer manifold isn't drilled for the ACT sensor. You will have to extend the ACT harness to relocate the ACT sensor to the air filter box. I went to Home Depot and found a brass fitting & some washers to secure the ACT in the airbox. I mounted the ACT up near the upper radiator hose in the stock air box.
Use the TPS and IAB from your old throttle body. All the EGR passages were there and fit OK. Use you old fuel rails and regulator. If you use the 65 mm throttle body, you will need a new EGR spacer adapter and gaskets. Without the EGR spacer, there is no place to mount the throttle linkage support bracket.
I used the stock water lines on the Explorer manifold and they connected up to the EGR without any problems. I made a “U” out of ½” copper pipe and sweat soldered it together. Then I used it and some hose with clamps to bypass the leaky heater I have. You don't need heat very often here in Central Florida...
The vacuum lines you need are 1 small line for fuel pressure regulator, 1 small line for A/C, 1 small line for EGR and another small line for the smog pump. One big line at the back goes to the vacuum tree for the power brake & A/C, the other big line goes out the front for the carbon canister. In a pinch, one of the small lines can connect to the spare port on the vacuum tree.
The stock Explorer linkage didn't come anywhere near fitting, so I made an adapter plate for the throttle linkage so I could use the 65 MM throttle body.
This is what I did:
Make a drawing of the position of the old throttle body linkage arm and its angular position relative to the centerline of the throttle body. Remove the ball stud off the explorer TB to make way for the adapter plate. Drill and tap a 10-32 hole in the linkage parallel to the TB shaft. Make an angle bracket out of 1" angle iron 3/8", drill a 3/16 hole in the center of each one of the legs. Then bolt it on where the hole was drilled & tapped. Then make a circular adapter plate out of 1/4" thick aluminum to bolt the two linkage arms together. Then bolt the aluminum plate to the existing linkage, and the angle bracket. Next mount the arm with the ball stud off the old throttle body on the adapter plate using the drawing to get the angle correct. You will need an aircraft type countersink for one of the bolts that secures the plate to the explorer linkage arm. It ends up being under the arm with the ball stud for the linkage. It works great and looks neat.
A trip to the welding shop with the explorer TB and the arm from your old Mustang TB would probably accomplish the same thing. I didn't have access to a welder, so I fabb'ed the plate in my shop. I took about 1.5 hours to do it, it was a measure, cut, and fit type of operation.