Pi intake on non pi heads

jenrik

New Member
Dec 9, 2016
14
0
1
49
I was wondering if anyone had any bad experiences with using the silicone when putting a pi intake on non pi heads on a 98 gt 4.6
 
  • Sponsors(?)


08GT500

Active Member
Jul 12, 2018
858
133
53
49
Massachusetts
Hi,
The PI intake differs than the stock replacement (NPI) intake, may look the same- closer inspection will reveal its differences. Unless you have a PI motor (99’-04’,) or have installed the PI
head swap you should run the stock NPI intake.
If installed on a (96’-98) motor without PI heads, it will likely cause leakage issues.. Not worth the risk. A stock NPI replacement intake can be found cheap at Rock auto, a local junkyard, etc.
If you do the full PI install, Heads/Cam/Intake, you’ll gain near 50hp with no tuning required. New PI parts are not ridiculously expensive, relative to gains. If you’re interested in that route, I can offer some lower cost alternatives.
There’s also adapters that Livernois makes allowing a PI intake install on a non PI motor.
Good luck!
John
 

jenrik

New Member
Dec 9, 2016
14
0
1
49
Hi,
The PI intake differs than the stock replacement (NPI) intake, may look the same- closer inspection will reveal its differences. Unless you have a PI motor (99’-04’,) or have installed the PI
head swap you should run the stock NPI intake.
If installed on a (96’-98) motor without PI heads, it will likely cause leakage issues.. Not worth the risk. A stock NPI replacement intake can be found cheap at Rock auto, a local junkyard, etc.
If you do the full PI install, Heads/Cam/Intake, you’ll gain near 50hp with no tuning required. New PI parts are not ridiculously expensive, relative to gains. If you’re interested in that route, I can offer some lower cost alternatives.
There’s also adapters that Livernois makes allowing a PI intake install on a non PI motor.
Good luck!
John
What kinda lower cost alternatives?
 

08GT500

Active Member
Jul 12, 2018
858
133
53
49
Massachusetts
What kinda lower cost alternatives?
Hi,
Hope the information will lower your cost(s). Whether you’re simply seeking to replace your OE intake with a cracked Coolant passage with a stock intake (96’-98’ stock , revised (NPI Intake) & leave it “as is”, or move on to yield the gains from a full PI swap.
You bought the PI intake, you’re now stuck with it-on a non PI motor.. correct?
96’-98’ Mustang GT 4.6’s were not the only motors that were PI upgraded. Crown Vic’s, F-150’s, Lincoln town cars with the 4.6l received the same PI mods, since you should stick with Windsor parts on a Windsor motor, Romeo on a Romeo, you can either take an NPI intake from an auto recycler off a 96’-98’ 4.6l to get it running right, without repurchasing another, or buy PI parts you’ll need that are already installed from the factory on a 99’-04’ 4.6l.
And there’s the 4.6L PI adapter plate that allows you to run the non PI heads, it’s thickness is very close to pushing the intake height into the hood, That’s at Livernois Motorsport
This link should help:
If you post what you’d like to do, don’t mind helping helping high
-Good luck!
-John
 

jenrik

New Member
Dec 9, 2016
14
0
1
49
Hi,
Hope the information will lower your cost(s). Whether you’re simply seeking to replace your OE intake with a cracked Coolant passage with a stock intake (96’-98’ stock , revised (NPI Intake) & leave it “as is”, or move on to yield the gains from a full PI swap.
You bought the PI intake, you’re now stuck with it-on a non PI motor.. correct?
96’-98’ Mustang GT 4.6’s were not the only motors that were PI upgraded. Crown Vic’s, F-150’s, Lincoln town cars with the 4.6l received the same PI mods, since you should stick with Windsor parts on a Windsor motor, Romeo on a Romeo, you can either take an NPI intake from an auto recycler off a 96’-98’ 4.6l to get it running right, without repurchasing another, or buy PI parts you’ll need that are already installed from the factory on a 99’-04’ 4.6l.
And there’s the 4.6L PI adapter plate that allows you to run the non PI heads, it’s thickness is very close to pushing the intake height into the hood, That’s at Livernois Motorsport
This link should help:
If you post what you’d like to do, don’t mind helping helping high
-Good luck!
-John
Well the thing is i dont have alot of money, and my current non pi intake has been leaking into my spark plug holes, and also the bolts that bolt the aluminum crossover to the intake have backed themselves out and of course they bolt on from underneath,.. and i just happen to have a pi intake, so figured if i had to pull the intake to fix the leak anyway i figured with all ive read about just adding the silicone to make the pi intake work and everyone saying they have no problems with it
 

tsemmett

Active Member
Jul 2, 2019
221
30
38
37
US
I read the same thing too, and gave it a shot about 3 years ago. I spent the next 2+ fighting coolant leaks until I finally gave up and bought a cheap knock off NPI intake. If your budget is a concern, do keep in mind that a PI intake swap requires a PI water pump nipple and heater tube, as well as a set of PI gaskets (over $90 new). The NPI intake I have was $135 (w/ a warranty).

That said, there is a noticeable performance improvement with the PI intake, especially over about 4k RPMs. But, the leaking wasn't worth the benefit. If I had to do it again, I'd have gotten a set of PI heads while I was at it and done the whole swap (I might still).
 

jenrik

New Member
Dec 9, 2016
14
0
1
49
I read the same thing too, and gave it a shot about 3 years ago. I spent the next 2+ fighting coolant leaks until I finally gave up and bought a cheap knock off NPI intake. If your budget is a concern, do keep in mind that a PI intake swap requires a PI water pump nipple and heater tube, as well as a set of PI gaskets (over $90 new). The NPI intake I have was $135 (w/ a warranty).

That said, there is a noticeable performance improvement with the PI intake, especially over about 4k RMs. But, the leaking wasn't worth the benefit. If I had to do it again, I'd have gotten a set of PI heads while I was at it and done the whole swap (I might still).
Yeah i know, im just not sure what route to go and with a low budget, it sucks money is a issue with me, but i have read soo much about that there is more gain with the pi intake and npi heads as opposed to pi intake and pi heads, but now i worry about the risk of more leaks
 

jenrik

New Member
Dec 9, 2016
14
0
1
49
Yeah i know, im just not sure what route to go and with a low budget, it sucks money is a issue with me, but i have read soo much about that there is more gain with the pi intake and npi heads as opposed to pi intake and pi heads, but now i worry about the risk of more leaks
My car is a stick so low end is not a problem, but seems like i need more top end, like halfway through 3rd
 

tsemmett

Active Member
Jul 2, 2019
221
30
38
37
US
A full PI swap is actually better overall, but the bulk of the improvement is in the cams and intake, which is why the cam/intake only swap is popular. The PI heads will give you a compression bump (around 10:1) which is worth 5hp or so. That may also mean higher octane fuel though. In my opinion, having matched ports (and not having to silicone them) is worth the extra cost/trouble.

Mine's a 5spd too; I know exactly what you mean.
 

08GT500

Active Member
Jul 12, 2018
858
133
53
49
Massachusetts
Well the thing is i dont have alot of money, and my current non pi intake has been leaking into my spark plug holes, and also the bolts that bolt the aluminum crossover to the intake have backed themselves out and of course they bolt on from underneath,.. and i just happen to have a pi intake, so figured if i had to pull the intake to fix the leak anyway i figured with all ive read about just adding the silicone to make the pi intake work and everyone saying they have no problems with it
Hi,
Little confused...So you’ve got the aluminum crossover on the Intake that’s now installed? That’s the NPI repair from Ford, if there’s a coolant leak it’d be highly unusual to be coming from there. Sounds like you just need to verify if the leak is coming from the head gasket surface(s), or thermostat housing, etc, repair that- then plan any upgrades after its functionally correct.
Can you see where the leak is, exactly..?
-John
 

jenrik

New Member
Dec 9, 2016
14
0
1
49
A full PI swap is actually better overall, but the bulk of the improvement is in the cams and intake, which is why the cam/intake only swap is popular. The PI heads will give you a compression bump (around 10:1) which is worth 5hp or so. That may also mean higher octane fuel though. In my opinion, having matched ports (and not having to silicone them) is worth the extra cost/trouble.

Mine's a 5spd too; I know exactly what you mean.
I guess i could head to junk yard at some point and look for maybe a wrecked 2001 mustang 4.6 and pull the heads, coolant tube and nipple that might be the cheapest route, do i use my timing chain? Or are they different also...i at first tried to find the gasket that whent between the aluminum crossover and plastic intake on my npi intake and was just gonna pull it off and replace the crosssover gasket but had no luck being able to find just that gasket....dumbe that they bolt those crossovers on from underneith and no way to get to most the bolts to re tighten without pulling entire intake
 

tsemmett

Active Member
Jul 2, 2019
221
30
38
37
US
If you get parts from an 01-04 Romeo engine, you should be fine; the 99-00 Windsor engines have a few differences that add to this. You shouldn't need a timing chain (assuming yours is good), but a lot of people do replace them while they have that apart. The nipple might be difficult to salvage: I had to beat my old one out with a small sledgehammer.

As for the o-rings that seal the coolant crossover; I'm not aware of any place to purchase them either. The only thing Ford sells for that anymore is the entire PI intake.
 

jenrik

New Member
Dec 9, 2016
14
0
1
49
If you get parts from an 01-04 Romeo engine, you should be fine; the 99-00 Windsor engines have a few differences that add to this. You shouldn't need a timing chain (assuming yours is good), but a lot of people do replace them while they have that apart. The nipple might be difficult to salvage: I had to beat my old one out with a small sledgehammer.

As for the o-rings that seal the coolant crossover; I'm not aware of any place to purchase them either. The only thing Ford sells for that anymore is the entire PI intake.
So it is better to get ones from a 01-04 correct? And i did find a kit for like $119 that has the nipple, tube and i think the alternator bracket, so thats not too bad, only other problem is the extra sensor on the aluminum crossover, it would have to be drilled in and tapped or i would have to swap my old npi crossover onto the pi intake, but then comes the problem again of not having a new gasket for the crossover
 

tsemmett

Active Member
Jul 2, 2019
221
30
38
37
US
Right, 96-98 and 01-04 are Romeo, and compatible in general.
I didn't need to use a different alternator bracket (ours does have the plug wire loom on it), but if you're getting heads from a parts yard, I'd grab it too. The nipple and hose are under $60 new at LMR; probably less at Rock Auto.

Yeah, you do definitely need to drill out another spot for the second coolant sensor. Without the gasket, I wouldn't swap the crossover either.
 

08GT500

Active Member
Jul 12, 2018
858
133
53
49
Massachusetts
Hi,
You don’t need to look far & wide for a Mustang, specifically- as stated above & previous. You’ll be hard pressed to find a 4.6l Mustang vs a Crown Vic. or F-150, etc.
Stick Romeo to Romeo (article posted earlier explains) for parts & you’ll have no issues. Dorman sells the O-rings as well as gaskets at various typical locations online, as well as locally in the usual part stores.
You can also purchase a PI intake from Livernois that’s been redesigned to fit the NPI heads, if you want to go that route.
Good luck!
-John
 

tsemmett

Active Member
Jul 2, 2019
221
30
38
37
US
Hi,
You don’t need to look far & wide for a Mustang, specifically- as stated above & previous. You’ll be hard pressed to find a 4.6l Mustang vs a Crown Vic. or F-150, etc.
Stick Romeo to Romeo (article posted earlier explains) for parts & you’ll have no issues. Dorman sells the O-rings as well as gaskets at various typical locations online, as well as locally in the usual part stores.
You can also purchase a PI intake from Livernois that’s been redesigned to fit the NPI heads, if you want to go that route.
Good luck!
-John
John, do you have a source for that Livernois kit? I've not seen it for sale in the last few years myself (I definitely don't find it on their site). I'd love to know if that's still a readily accessible option.
 

08GT500

Active Member
Jul 12, 2018
858
133
53
49
Massachusetts
Hi,
I have to apologize, they are officially “no longer stocking this part”. I usually give links to parts for people to locate easier..one time I don’t-Grrr..I’d actually just called Livernois to get the bottom line on the intakes, as many of their products have, historically been easier to locate with a phone call- (Site really..sucks) which I’d also done years ago and bought 3 of them due to demand.
I dug a bit further & they’d informed me the line has, indeed- been indefinitely discontinued, due to inability to “get the intakes”. They wanted near 550$ for it, which makes it effectively ridiculous.
Sorry for the lackluster lead, i’ll look around & see if I can locate something, they sold a lot to other vendors.
 

tsemmett

Active Member
Jul 2, 2019
221
30
38
37
US
No worries. I was hoping I had missed something; that might have been an ideal solution to my scenario too. Thanks!
 

08GT500

Active Member
Jul 12, 2018
858
133
53
49
Massachusetts
No worries. I was hoping I had missed something; that might have been an ideal solution to my scenario too. Thanks!
Yeah, I regret that isn’t still an option, tell you what- I am an engineer, can draw them up exactly as needed in solidworks/Autocad360 & send quotes out to injection molding & 3D printing Companies all over the world, just start manufacturing them for a reasonable cost & make millions of dollars & make SO many Ponylover’s ecstatically happy at the same time?
 
Thread starter Similar threads Forum Replies Date
F non pi head/pi cam and pi intake hp gains SN95 4.6L Mustang Tech 28
G Finally, a PI Intake to a Non-PI Heads Adaptor Kit! SN95 4.6L Mustang Tech 9
Back2Mustangs PI Intake on NON-PI heads (what parts r needed?) SN95 4.6L Mustang Tech 2
A Engine egr or non egr gt40 intake Fox 5.0 Mustang Tech 1
5spd GT Does anyone still cover the cracked non-pi intakes? SN95 4.6L Mustang Tech 7
Busted07 Questions about timing cover, water pump and non-efi intake install Fox 5.0 Mustang Tech 12
GT_Rich Need non-pi intake w/ alum cross over! SN95 4.6L Mustang Tech 17
B Non-PI Intake part number SN95 4.6L Mustang Tech 4
MrKwik HO vs. non-HO intake , how to tell? Fox 5.0 Mustang Tech 10
9 pi intake swap on non pi SN95 4.6L Mustang Tech 5
moneypit94 Here is a non-traditional intake? How/Why? 1994 - 1995 Specific Tech 11
2 Intake change on non mass air car ?? Fox 5.0 Mustang Tech 6
H Will 75mm elbow work with a non-ported Performet intake? 1994 - 1995 Specific Tech 12
J 2006 Mustang V6 backfire or popping in intake. Any ideas how to find the issue? I don't see any vacuum leaks, all plug wires are on tight. 2005 - 2014 S-197 Mustang -General/Talk- 2
Habu135 Expired 3" ID Cold Air Intake w/K&N Engine and Power Adder 0
M Intake replace help 1996 - 2004 SN95 Mustang -General/Talk- 2
2007_Crown_Vic Engine Explorer Intake Fox 5.0 Mustang Tech 2
Mustang5L5 Engine Explorer intake vacuum line diagram Fox 5.0 Mustang Tech 4
F Engine Getting my GT40 Intake ported, to Keep EGR or Not? Fox 5.0 Mustang Tech 26
D Engine Oil in Intake, normal? 1994 - 1995 Specific Tech 15
foxbodybill89 Engine convertible/explorer intake hood clearance Fox 5.0 Mustang Tech 2
W Mach1 2003 coolant leaking rear of engine SN95 4.6L Mustang Tech 2
gearhead77 Engine Valve cover/ intake studs and other stuff Fox 5.0 Mustang Tech 15
markinms Engine Explorer Intake Swap Performance Issues - Need Help! Fox 5.0 Mustang Tech 10
65ShelbyClone SOLD WTB Weiand Stealth 302 or Summit Stage 2 intake manifold Engine and Power Adder 0
R Engine setting valve lash on stud mounted roller rockers with intake already installed. 1994 - 1995 Specific Tech 4
5 Intake manifold/ general mod advice 1979 - 1995 (Fox, SN95.0, & 2.3L) -General/Talk- 3
T 4 brrl intake/carb combo for stock 1966 fastback 289 1965 - 1973 Classic Mustangs -General/Talk- 2
J Engine Trickflow Intake Street Burner Spacer Needed? Fox 5.0 Mustang Tech 13
T 2016 Mustang GT *Random Misfire's CEL* Charge Motion Valve "Flaps" in Intake Manifold 2015+ (S550) Mustang -General/Talk 5
R Engine Smoke test for possible leaking lower intake gasket Fox 5.0 Mustang Tech 0
91GTstroked Engine Changing lower intake gaskets Fox 5.0 Mustang Tech 15
K Best way to clean 4.6L DOHC upper and lower intake manifolds? 1996 - 2004 SN95 Mustang -General/Talk- 3
91GTstroked Engine Lower intake vacuum leak Fox 5.0 Mustang Tech 7
R Engine My on going lower intake dilemma w/pics Fox 5.0 Mustang Tech 14
92j3ieje8 How long to wait before removing intake manifold? 1996 - 2004 SN95 Mustang -General/Talk- 2
D F-150 4.2 Intake Manifold on V6 Mustang? SN95 V6 Mustang Tech 1
BETTERBULLITT Intake plastic nipple broke, antifreeze spewing everywhere. Now what? 1996 - 2004 SN95 Mustang -General/Talk- 5
Ultra90GT For Sale 351w GT40 tubular intake + extras Engine and Power Adder 0
P Looking to get a Intake plate 1979 - 1995 (Fox, SN95.0, & 2.3L) -General/Talk- 0
S 2000 3.8l lower intake 1996 - 2004 SN95 Mustang -General/Talk- 0
R Engine Upper intake & Components - Carbon buildup? Fox 5.0 Mustang Tech 4
02 281 GT LMR is making an ‘89-‘93 stock intake tube repro 1979 - 1995 (Fox, SN95.0, & 2.3L) -General/Talk- 13
B Engine Questions regarding a 93 Cobra Vacuum Leak/Intake Manifold Fox 5.0 Mustang Tech 6
D intake manifold bolts 2006 base The Welcome Wagon 0
65Stang86 WTB/Trade Looking for used edelbrock 7121 performer rpm intake manifold Engine and Power Adder 0
T What are these in the 3.8l Intake SN95 V6 Mustang Tech 4
S New Guy 2003 GT looking for intake manifold upgrade recommendations SN95 4.6L Mustang Tech 1
R Engine Ford Explorer GT40 intake and heads Fox 5.0 Mustang Tech 11
A Installing BBK SSI INTAKE 1979 - 1995 (Fox, SN95.0, & 2.3L) -General/Talk- 4
Similar threads