96 intake swap+Turbo=headache

[RedZMonte]

so i tore the intakes out of the car, replaced the lower and swaped fuel injectors over... Everything looked good from there out.... (got the 1995 valve cover gaskets to work on the '96 valve cover (very simmilar)) set the upper intake on to check for problems, looks good.... went to attach the TB arm... F me! the fuel lines that attach to the fuel rail don't clear the downpipe... tried the old lines, looks good untill the tb arm gets put back on, no go....

So now ive got 2 options
* try to make custom fuel lines (hard lines) w/ the correct fittings for the quick connects
* modify what ive got and make a new intake/TB arm

it was feeling good untill i got almost done and hit a wall...

S

[1988GTU]

1. make new hard lines.

[IsaacHayes]

Yeah, the correct flare and unions to join them back in, custom bend what you need in between.

[d.o.h.c]

Shane, let me know whats all needed to do this. I would love to know what you gained as well for power.

Mark

[RedZMonte]

Shane, let me know whats all needed to do this. I would love to know what you gained as well for power.

Mark

http://60degreev6.com/content/9697_Intake_Manifold_Swap_9195_Engines?

1996-97 upper intake manifold/throttle body/intake arm
1996-97 lower intake manifold/T-stat housing
1996-97 fuel rail
intake gasket kit (cheaper from dealer then felpro)
throttle body gasket (dealer)
intake manifold to intake arm gasket (dealer)
1996-97 throttle cable (maybe)
1996-97 Rear valve cover (or remove breather nipple from yours, 96-97 has no breather)
1996-97 plug wires (or modify yours like im going to do)
1996-97 coolant pipe (from front of engine to lower intake)
im going to block the coolant to the TB for ease of install with turbo
coolant hose to heater core... im reusing my original hard line to the heater core.
I have to make custom hard lines for the fuel rail because of the turbo/DP.
Also need all the intake bolts (different the the ones in there now)
PCV hose, random vac lines... pretty much everything that connects to the intake arm/TB.

i also repalced the VC gaskets and plugs while its apart. it is incredible how much more volume the 96-97 plennum has over the '95. I also replaced a few of the sensors and FPR so i wouldnt get any suprises.I will get some pics.

S

[d.o.h.c]

I am just worried cause I have alot powdercoated and what not. Also I really dont want to hack up my magnacore wires. I am interested to see power gains (atleast what you feel it does). My personal opinion is that the 95 and lower dohc's has terriable intake manifolds. with a sheet metal intake manifold and a 75-80 mm TB these cars would fly, especially with a good size turbo.

Mark-OEm

[RedZMonte]

honestly you can make a new intake arm out of steel or aluminum and run any TB you want, there is definatly enough volume there. the inside of the plennum on the 96-97 is pretty damn large... i was very supprised... also i have mangnacore wires, i think i just need to trim the plastic that sticks up, the wires are not going to be touched or maybe just swap the boots. you cant see them and they will still be functional.

[d.o.h.c]

Humm good point. Well the new FP is going in tomorrow so I can boost again, finally. Not to steer away from your topic but please let me know what you find out and so on. Very interested to see the end results.

Mark-OEm

[RedZMonte]

O-Key-Doe-Key

[1988GTU]

ITB with boost to each TB. DOOO ETTTTTTTT!

[RedZMonte]

who wants pics?

Big ass Mess under my hood now:


X-over and DP:


96 Lower intake and injectors:



95 lower intake:


TB Coolant 1/8" from downpipe :


'96 vs '95 plennum comparison:


Inside the '96 Plennum (WIDE open, I hope she likes boost)


Hope you like

S

[IsaacHayes]

Nice. I would think a large plenum would work in the way a larger air tank does. Once filled the draw does not make the PSI drop so much from the compressor. But might take a bit longer to fill... Those ports should help for sure. Give me your TB... that breather tube has a right angle my LX5 one doesn't which would be helpful... LOL

[d.o.h.c]

Very cool indeed.

[RedZMonte]

Got some new pics... Everything is done but i need new throttle cables, stock '95 DOHC cables will definatly not work. how hard are the throttle cables to swap? im sure its not to bad, just never looked.. Also can you swap the Cruse control cable or is it all built on to the CC module? it might be easier than finding a '96-97 Cruse module w/ Cable..

Engine shot:


Trimmed intake arm (bypassed coolant):


New piping setup to TB... TIGHT but do-able:


Another engine shot:


Had to do a little custom modifying the fuel lines (originally hard now SS Braided):



Shane

[d.o.h.c]

Sweet. What size lines you using for fuel? I ran -6AN.

Mark-OEM