PI Intake Manifold Install Issue

97Vicious281 · Sep 18, 2011

How's it going guys. I've been doing the PI Intake Manifold swap on my 97 GT, and it has gone fine up until this point. I've got an issue getting the water pump nipple off of the back of the pump in the valley of the block. Here is a link to the install guide from American Muscle.

How To Install A Mustang PI Intake - Installation Instructions at AmericanMuscle.com

If you check out pictures 8 & 9 you will see the nipple that I'm talking about. I've got the new one ready to go, but I can't get the original out. I've tried to use a set of channel locks but that has only gotten it to the point of my having to cut a piece off of the end of it since it clamped down on it.

Any comments/suggestions would be greatly appreciated because this is the only thing holding me up from putting it all back together.

Thanks.

wmburns · Sep 18, 2011

Have you tried driving it out with a rubber/plastic mallet or a block of wood?

Have you used any penetrate (PB blaster, Kano labs Kroil, WD40, anything?)?

Can you post pictures?

97Vicious281 · Sep 18, 2011

Not exactly sure how to drive it out with a hammer. I've taken the water pump out and can just insert a screwdriver all the way through. PB blaster was my next approach. Let me go take some pictures of it.

97Vicious281 · Sep 18, 2011

@WMBurns

Here are a few shots of it.

I couldn't upload more than 2 on here, but I added them onto my website under this directory: Index of /intake

97Vicious281 · Sep 18, 2011

Here are 2 more.

nyuk98gt · Sep 18, 2011

97ViciousGT:

Mr. Burns is correct: use a small block of wood as a pad and tap the nipple out. Heat (propane torch with a small flame) or PB Blaster are good aids. That nipple has been in the same spot for 14 years. There is one, maybe two, o-rings on the nipple and they are probably dried out adding to the sticking problem.

Keep at it. You will get that little thing out of there.

HTH,

Chris

wmburns · Sep 18, 2011

At the risk of stating the obvious (again), which way are you trying to remove it (towards the front or rear)?

It's a press fit, so likely some penetrating oil should be used. If you can get some Kano Kroil, this stuff really does everything it says. Even flows uphill. Highly recommend.

Penetrating-Lubricating Oils

The WEB site link is "404".

nickmckinney · Sep 19, 2011

You need a small sledge and it will pop right out:

Another install article here:

Click me

Lugnuts · Sep 19, 2011

I am with these guys. From the pictures it appears that you are trying to pull it out on the valley side. It comes out the pump side. You may want to try to use a drive tool or a large screwdriver with a hose clamp on it to get it started as the tube portion appears to be weakened.. This would keep the tube from splitting and transfer the force to the rest of the fitting. Remove the hose clamp once you get it started and make the tube as round as possible - you do not want to scar the ID of the hole or you will have the potential for a leak.

97Vicious281 · Sep 19, 2011

Ahhh I didn't know it came
Out of the pump side. I'll give that a try tomorrow. Thanks for all the help.

apats77 · Sep 23, 2011

I just did this install on my 98 lemme know if you have any questions.

If you go to my thread in SN95 4.6 Talk, its called My 98 GT, there is a picture of the RTV in the coolent port.

COramprat · Sep 28, 2011

For future reference, take a socket that just fits over the end of the nipple. That way when you tap on it it doesn't flare out and make it harder to remove.

2002BLGT · Sep 28, 2011

I find it irresponsible for a company as big as American Muscle to put a write up on installing a PI intake on a NPI car without the use of adapter plates like the Livernois kit comes with , I think if American Muscle wants to sell PI intakes to guys with NPI heads then they need to have someone make adapter plates to do the install properly , install also mentions nothing about drilling and tapping for the 2nd coolant sensor

Here is the proper way to do it
http://www.livernoismotorsports.com/products/1996%2d1998-4.6L-PI-Intake-Adapter-Kit.html

97Vicious281 · Sep 28, 2011

Yeah the second sensor is the only thing I've yet to do and it's throwing an error. Thanks for the link.

5spd GT · Sep 28, 2011

97Vicious281 said:
Ahhh I didn't know it came
Out of the pump side. I'll give that a try tomorrow. Thanks for all the help.

This should take care of that issue for you.

Here is a little portion I wrote some time ago, for those that come across this in a search, since everyone is linking very helpful articles.

PI Intake Swap Checklist Install Help:

Excellent Intake Removal and Replacement Article

Intake Torque Sequence

01+ PI Intake Gasket* – YL3Z-9439-BA -(1 each for a total of 2) – or FelPro – MS-92121
96-98 NPI Intake Gasket - XW7Z-9439-AA
Alternator Bracket - F8AZ-10153-EA – 96-98 with PI Intake/Al. Crossover - (1 brkt)
Coolant Tube – XR3Z-18B402-AA - (1 tube)
Coolant Nipple – F75Z-8555-AA – (1 nipple)
Upper Plenum O-Ring – XR3Z-9L437-BA – (1 o-ring)
Thermostat O-Ring – F1VY-8255-A – (1 o-ring)
Water Pump O-Ring – F1VY-8507-A – (1 o-ring)
Stock or 180* Thermostat – 3L3Z-8575-AC (192*) or XL3Z-8575-AA (180*) - (1 t-stat)
Thermostat Housing Bolts*: N811011-S309

* - If installing a PI Intake on Non-PI heads use PI intake gaskets and you will need to RTV in a few spots to prevent leaks.
** - Optional

Before installing the intake, install the heater tube over new coolant nipple and bolt it to the back of the driver side head. Using a Windsor head (99-00) will require you to drill out heater tube bracket hole and use a larger bolt.

Tap PI intake - 3/8-18 NPSF with Pipe Thread. Same tap as passenger side coolant sensor.

Install intake gasket dry. Move all sensors over from NPI to PI manifold. Thread sealer on front two coolant sensors only.

Be easy on brass inserts with no more than 106 inch lbs (8 ft lbs.)

Install thermostat with spring pointing down and install thermostat gasket dry on top of the thermostat.

Install plenum gasket dry.

Gap and install spark plugs with a little antiseize on threads and torque to 13 ft. lbs.

nickmckinney · Sep 28, 2011

2002BLGT said:
I find it irresponsible for a company as big as American Muscle to put a write up on installing a PI intake on a NPI car without the use of adapter plates like the Livernois kit comes with , I think if American Muscle wants to sell PI intakes to guys with NPI heads then they need to have someone make adapter plates to do the install properly , install also mentions nothing about drilling and tapping for the 2nd coolant sensor

Here is the proper way to do it
1996-1998 4.6L PI Intake Adapter Kit - Livernois Motorsports

Actually those adapter plates throw off the injector timing and spray pattern since they move the injectors away from the original location. Best way is weld the corner of the NPI water outlet (what I do) second best is RTV with a PI gasket.

2002BLGT · Sep 29, 2011

nickmckinney said:
Actually those adapter plates throw off the injector timing and spray pattern since they move the injectors away from the original location. Best way is weld the corner of the NPI water outlet (what I do) second best is RTV with a PI gasket.

I would still do adapter plates before I would ever trust RTV on something like that

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