pi intake swap help

Ryan441 · Oct 2, 2008

im swapping to a pi intake manifold and i cant seem to find and pics of where and how much rtv to use. also ive read many threads and some use the npi gasket and others use the pi gasket witch should i use? where your supposed to tap a hole for that sensor on the front of the manifold, what exactly does that sensor sense because it seems like it is just reading the water temp twice and i was thinking why not just splice the wires from that one to the other so there is only one sensor but the computer still gets the reading it needs. i also got a bigger fuel rail should i put it on or sell it? any gains from it?

98COBRA281 · Oct 2, 2008

hope this helps....

RysRed96GT · Oct 2, 2008

Man, this brings back memories.

I did mine the same way using the newer PI gaskets and a nice gob of the sealant near the coolant holes. Worked fine until I got a set of heads cheap.

For the sensor, I actually tapped into my t-stat housing (the silver dome). I don't recall the measurements, but it has worked out nicely over the past 4-5 years. I know the sensors are different on our cars - they each measure it differently. I don't recall which one I used there.

Also, be sure to pick up a new coolant tube if you haven't already, the one that runs along the block, as it needs to clear the longer runners of the intake. The old one will not work. I used an L-shaped rubber hose and a couple clamps, sawed off the end of the front of the tube and got it working nicely - very easy.

Hope this helps.

Ryan441 · Oct 2, 2008

is that a npi gasket? what does the second sensor do?

RysRed96GT · Oct 2, 2008

Ryan441 said:
is that a npi gasket? what does the second sensor do?

The gasket in the pic is a PI gasket.

I can't answer the sensor question, but I can look at my car after work and see where the wires are coming from for the one on the tstat housing.

COramprat · Oct 2, 2008

One sensor is for the gauge, the other for the computer. Not sure which, which is which. Not a good idea to splice and use just one as it could give a false reading and goof with computer parameters. Some tap the T-stat housing, others have used a freeze plug at the bottom of the engine block on the drivers side. It was blocked on my 96 by the k-member/engine mounts but I think the 98 had a free shot to it. I just tapped the space on the new manifold for the second sensor.

Ryan441 · Oct 2, 2008

what size tap and drill bit do i need. so i do need to go get a set of pi gaskets. this seemed like a very easy swap but now it seems a little more complicated or maybe im just getting a little confused

98COBRA281 · Oct 2, 2008

you will alos have to change the coolant tube that runs underneath the intake manifold, because the pi intake sits lower......

Ryan441 · Oct 3, 2008

could i just run rubber hose the hole way instead of the tube? i mean there might be a reason for it but i really dont see one. i called discount and they said they dont list the coolant tube so where would i get it from? maybe just use a flex tube? i got a fitting to put both sensors in and one is for the computer to turn the fan on and the other is for the temp gauge.

98COBRA281 · Oct 3, 2008

Ryan441 said:
could i just run rubber hose the hole way instead of the tube? i mean there might be a reason for it but i really dont see one. i called discount and they said they dont list the coolant tube so where would i get it from? maybe just use a flex tube? i got a fitting to put both sensors in and one is for the computer to turn the fan on and the other is for the temp gauge.

yes you can run a rubber hose, and use a hose clamp to clamp it to the nipple that comes out the back of the water pump

COramprat · Oct 3, 2008

The coolant tube only comes from Ford but your idea should work.

Ryan441 · Oct 4, 2008

i installed the manifold and it doesnt seem to be leaking coolant or anything, but i cant fig out where the red vacuum line that connects to the plenum and the fuel rail goes to on the pass. side.

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