putting in a new intake.
- Thread starter schwbs5.0
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88stangmangt
Active Member
not hard just take your time mark all the wires!!!! and make sure you use the right torque specs.
It's not terribly hard if you have a general idea of what you're doing and take your time. Label your vac. lines for easy reinstallation. I tied the wiring harness back up against the windshield when I did it..those 10 pins are hard to get apart and I didn't wanna mess w/ it. Be sure to clean your gasket surfaces really well. Use a gasket scraper and then clean it w/ brake cleaner or gasoline. Personally I lightly sanded mine w/ sandpaper also.
I personally suggest the lower intake gasket set w/ the rubber ends and I believe I got mine at O'Reilly's for like $25. The cork ends suck(had leaks more than once with them) and I don't feel confident w/ just permatex like some people do. Use the rubber ends and put some permatex on top of them, but not a lot because you don't want it squishing all over the place. Be sure to put dabs of permatex in each corner where the end gaskets meet the heads.
Be sure to use a torque wrench and and if you don't have one, you could maybe borrow one from autozone or a friend. Torque in sequence found in your manual because I'm sure you have a manual to refer to when doing something like this
A really awesome and very helpful tip I got from Michael Yount was to get 4 bolts the same size (7/16?) as your lower intake bolts and get them about 2" long or so--chop the heads off, slit the ends w/ a dremel or handsaw and use one in each corner to get your lower lined up--then you can just drop it right over them w/o having to worry about line-up issues
It works very well and you can also use the same "dowels" for the upper intake--or at least they're the same on my GT-40.
I used an old vac, but a shop vac would be best to suck up any left over gasket material or anything else you wanna vac out while the lower is off, etc. and don't forget to drain your coolant at least far enough to get it out of the lower.
You might also consider changing the O-Rings on your fuel injectors while you have them out. I suggest just pulling the old rings off over the pintle caps (little "hats" on the bottoms) and replacing the new ones w/ vasiline over the pintle caps. I'd only replace the caps if yours are lost or broken because they are a pain to get off/on w/o breaking. This is a quote from Jrichker:
"Fuel injector seal kits with 2 O rings and a pintle cap (Borg-Warner P/N 274081) are available at Pep Boys auto parts. Cost is about $2.74 per kit. The pintle caps fit either injectors with a pin sticking out the injector end or 4 with more tiny holes in the injector end. The following are listed at the Borg-Warner site ( http://www.borg-warner.com ) as being resellers of Borg-Warner parts:
http://www.partsplus.com/ or http://www.autovalue.com/ or http://www.pepboys.com/ or http://www.federatedautoparts.com/
Most of the links above have store locators for find a store in your area."
Also, since you're in there already, replace your PCV valve and screen. Many people suggest the kit from ford for like $17 or $18 w/ both the valve and screen together and I think maybe a grommet, but i'm not sure.
I'll try to get you a parts list, although I may miss a few things:
Gasket scraper
Brake cleaner or gasoline
Permatex
Lower Intake gasket set (I suggest rubber ends)--ford dealer should have it if others don't
Upper intake gasket.
Throttle Body gasket
EGR gasket
IAC gasket(I used my old one)
Thermostat housing gasket
PCV Valve and screen
Injector O-Rings
I personally suggest the lower intake gasket set w/ the rubber ends and I believe I got mine at O'Reilly's for like $25. The cork ends suck(had leaks more than once with them) and I don't feel confident w/ just permatex like some people do. Use the rubber ends and put some permatex on top of them, but not a lot because you don't want it squishing all over the place. Be sure to put dabs of permatex in each corner where the end gaskets meet the heads.
Be sure to use a torque wrench and and if you don't have one, you could maybe borrow one from autozone or a friend. Torque in sequence found in your manual because I'm sure you have a manual to refer to when doing something like this
A really awesome and very helpful tip I got from Michael Yount was to get 4 bolts the same size (7/16?) as your lower intake bolts and get them about 2" long or so--chop the heads off, slit the ends w/ a dremel or handsaw and use one in each corner to get your lower lined up--then you can just drop it right over them w/o having to worry about line-up issues
It works very well and you can also use the same "dowels" for the upper intake--or at least they're the same on my GT-40.I used an old vac, but a shop vac would be best to suck up any left over gasket material or anything else you wanna vac out while the lower is off, etc. and don't forget to drain your coolant at least far enough to get it out of the lower.
You might also consider changing the O-Rings on your fuel injectors while you have them out. I suggest just pulling the old rings off over the pintle caps (little "hats" on the bottoms) and replacing the new ones w/ vasiline over the pintle caps. I'd only replace the caps if yours are lost or broken because they are a pain to get off/on w/o breaking. This is a quote from Jrichker:
"Fuel injector seal kits with 2 O rings and a pintle cap (Borg-Warner P/N 274081) are available at Pep Boys auto parts. Cost is about $2.74 per kit. The pintle caps fit either injectors with a pin sticking out the injector end or 4 with more tiny holes in the injector end. The following are listed at the Borg-Warner site ( http://www.borg-warner.com ) as being resellers of Borg-Warner parts:
http://www.partsplus.com/ or http://www.autovalue.com/ or http://www.pepboys.com/ or http://www.federatedautoparts.com/
Most of the links above have store locators for find a store in your area."
Also, since you're in there already, replace your PCV valve and screen. Many people suggest the kit from ford for like $17 or $18 w/ both the valve and screen together and I think maybe a grommet, but i'm not sure.
I'll try to get you a parts list, although I may miss a few things:
Gasket scraper
Brake cleaner or gasoline
Permatex
Lower Intake gasket set (I suggest rubber ends)--ford dealer should have it if others don't
Upper intake gasket.
Throttle Body gasket
EGR gasket
IAC gasket(I used my old one)
Thermostat housing gasket
PCV Valve and screen
Injector O-Rings
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