95 3100 to 3400 intake swap?

[seanzyyy]

I have a 95 3100 engine that I would like to swap a 97 3400 upper and lower intake manifold onto. I see the EGR is a little different, as I have the EGR that is in this picture:

http://wot-tech.com/images/manifolds/9499/95to00adapter.jpg

I won't be getting a 00+ intake however, so this isn't the adapter I will need. I am assuming I will be needing this one, correct?

http://wot-tech.com/shop/all/90-95-egr-to-96-99-manifold-adapter/prod_9.html

It says I also need "96 3100 EGR Flex Pipe (or complete rear manifold)." Where is the best place to buy this pipe as I don't believe I have it?

Also I read that I will need to clearance the rocker arms. How much machining needs to be done? Is this something simple enough to do yourself with a dremel tool or grinder?

And lastly is there anything else I will need to deal with? I plan on reusing all the 3100 fuel rail assembly and tb (for now).

[SappySE107]

97 are the worst large port manifolds to use but they are an improvement over your stock manifolds. That is the right adapter for EGR. The EGR flex pipe is a dealer item or junkyard. Clearancing for the rockers sucks. I use a die grinder and would imagine hours of dremel work along with test fitting will be needed to make sure you have enough removed.

I would get a 3400 throttle body to get more out of the swap, but it isn't necessary.

[bszopi]

I would say, before you start clearancing the lower manifold, check you heads to see if they have the notches for the roller rockers. If so, that would be a worthwhile upgrade. You have to be really careful when grinding down on the manifold, as depending on the casting, it is easy to grind too much and go right through the port.

[IsaacHayes]

when testing the grinding, pull the spark plugs and turn the engine over with a ratchet, and watch slowly the rockers for hitting. That's how you test.

[seanzyyy]

Am I going to notice any major difference by doing this now, or would I be better off just waiting until I have the money to do a proper top end swap including heads with rollers and all? I'm guessing I would be better off using a 2000+ manifold instead, and to prevent buying multiple swap parts I may just wait on this until I get my hands on some roller heads and 2000+ manifold. I really like the look of the 3500 manifold so I may try to locate one of those. I have the engine out right now to replace a tranny, and wanted to do the intake manifold gaskets at the same time because I don't know the history of the car/engine and haven't a clue if they've been changed already. Figured I might swap the newer intake on it, but now its sounding like a bit too much rocker arm work to want to deal with.

[bszopi]

Take a look at the heads and see if there are notches under the guideplates.



If you have those, then I would do the swap and include a set of the roller rockers. If not, then yeah, it would probably be better to save up and do everything at once.

[seanzyyy]

Thats a big negative on my heads having those grooves. So I'm guessing I have some early generation heads that will not accept roller rockers and I will be stuck with needing to clearance regular rockers or purchase some new heads correct?

[bszopi]

Yes.

[IsaacHayes]

If you go slowly and carefully, you can grind the LIM for clearance. I did on mine.