Plastic Intake

[ronclark]

I am doing a 4.0L swap and it came with a plastic intake, is there anyway to make it work with a 93 harness?
I need to block the EGR hole and there is no placement for the Air temp sensor.

 

[Ranger44]

I think you need to worry about more than the intake.

My suggestion is to just go snag an aluminum upper and fuel rail(with red top injectors) from a 93 or 94' Ranger or explorer.

The fuel injectors are different than the ones you have on that newer 4L, and they will not run properly with the 93 PCM....

 

[ronclark]

I have red top injectors.
i just would love to use the plastic intake it looks so much cleaner

 

[BlackBII]

I just did a plastic intake swap.

You will need a rubber expansion freeze plug for the EGR hole, 1 3/8" if I remember correctly.

For the IAT, I drilled a hole in the side of the intake plenum, just forward of the vaccuum ports, and then heated the plastic with a heat gun, then threaded the IAT into the hole while the plastic was still soft. Worked perfectly. Just make sure you don't drill it too large!!

The plastic intake's flange is thicker, so you will need the longer studs in order to bolt it down. (If it's already on the motor, you wont have this problem.)

Everything else bolted up and worked great. Vaccum lines were cake.

 

[ronclark]

Sweet,
My studs are long enough. I have it just siting on the intake to keep out what ever might fall inside the last thing I want.
I am guess the I just need get a plug to match the idle valve.
Do you have any pics of your swap?
So far how's the swap been?

 

[BlackBII]

Sweet,
My studs are long enough. I have it just siting on the intake to keep out what ever might fall inside the last thing I want.
I am guess the I just need get a plug to match the idle valve.
Do you have any pics of your swap?
So far how's the swap been?

I can get some pics.

I like the swap. The intake runners are larger on the plastic intake than the aluminum one. They now match the lower intake much better. I definitely noticed a difference in my powerband, it moved up a few hundred RPM. According to my butt dyno, I gained like 7 hp. And it looks better too.

 

[ronclark]

I was more into it since it looks way better and cleaner.
That and I figure the inside stayed pretty smooth for better airflow

 

[Ranger44]

If you have a newer engine, and are using the injectors with that newer engine (95+), the injectors will not work with a 93' PCM.

 

[Yellowsplash]

You will need a rubber expansion freeze plug for the EGR hole, 1 3/8" if I remember correctly.

Yea....I put this info out a while back after removing the egr and came up with this solution, but its been too long to remember the correct size. The more I think about it the more I feel its closer to 1 1/16"... If your unsure, just take a caliper to it to get an accurate measurement and go from there.

 

[ronclark]

There sould be write up in the tech lib about this