96 GT NPI 4.6 to PI 5.4 Swap. (Pic) Starting on 1/21/06 Dark_Horse
01-19-2006, 06:25 PM
#1
3rd Gear Member
Thread Starter
Join Date: Oct 2005
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Posts: 850
96 GT NPI 4.6 to PI 5.4 Swap. (Pic) Starting on 1/21/06 Dark_Horse
ok so the plan is this weekend (1/21/06) i am going to start on my swap, i will take pictures, post them and make notes of whan needs to be changed to make the swap. Here is some pictures of the motor right now. I will update this post when i get new pictures. Hope it goes well.
EDIT:
got bored so i decided to start early, here is what i got so far.
1/19/06
First thing i did was remove the hood, then i put it up on jack stands, drained the oil and coolant.
Removed upper plenum, intake vacuume lines, wiring harness, Coil packs & wires
intake manifold, water pump pulley, alternator, & Electric fan
here is most of the parts that got removed, so far.
1/20/06
side shot of the 4.6 & 5.4 fuel rails
Top
if you look at the red circles (fuel perssure regulators, you will see that the 4.6 can be un bolted and replaced with a after market one, and the 5.4 has a inner snap ring that holdt it inplace. is there after marked fuel press. regulators for this one?)
the green are the quick connect fitings, they are on opposite sides so the fuel lines must be extended to reach. and yes you have to use the 5.4 fuel rail, i put the 4.6 rails on the 5.4 intake and they didn't fit that well... im sure you can make them go on but ill just use the 5.4 rail.
Stock NPI 4.6 intake manifold. has two coolant temp sensors.
5.4 PI intake with aluminum cross over.(only one temp sensor) the green circle on the left was a coolant nipple that went to the heater core. i din't know what it went to so i hacked it off, i milled it down and taped it so i can have both temp sensors in. but later i realized what it was for... the heater core
so i made this... this is going to go on the upper raidator hose and then the nipple will be ran back to the heater core.
1/21/06
a notch had to be cut so the oil pressure sender can be put on.
compairing the two Engines
compairing the two manifolds
these bottom two baffels need to be bent down 1/2 inch
my girl friend wanted me to, lol.
do this befor it goes in un like me so you dont have to pull it out them put it back in.
the passenger exhaust manifold has a casting lump that there is no need for so that had to be cut off for some clearance.
**Do this befor it goes in un like me so you dont have to pull it out them put it back in**
tilting the engine helps get it in/out
Makeing room for the intake so i had to mount the coil on the strut tower
... befor the motor is installed cut this are out, (where it is hammered) the EGR needs room so it is not on the fuel lines. and you also need to add 1 inch to the EGR tube right next to the EGR valve, you can strech/ and bend in the right places to make the 4.6 fit the 5.4. i used the 4.6 because there is no room for the 5.4 egr tube.
Whats that in the scoop?
Now dosn't that look AWSOME!
yes it dose hit on a 3" cowl hood with a SVO scoop. but only on the intake. it can move down
comming close...
oh and if you are going to do this and you have a PI mustang buy the addapter plates they are like $350 and you can use the stock 4.6 intake and notch your the under side of the hood but its not visable form the top. it will make every thing a LOT easyer, belive me. and the runners are shorter on the 4.6 so it will help make a little more hp then the 5.4 intake will. the 5.4 intake with loe longer runners will make more low RPM Torgue and less High RPM HP the 4.6 intake will do visa versa.( i would recommend the 4.6 with addapters)
1/23/06
Exhaust
ok so to make the exhauset fit... i cut the H in half so i can do one side at a time the Driver side fits perfect no modifications needed
Ther passenger side i either need to remove the lower stud to get it on, or can i cut the flange like this and then just bolt it on, im leaning to cutting the flange because it will be easyer then removing the stud if i have to take it out later.
[IMG]http://memimage.cardomain.net/member_images/12/web/456000-456999/456787_481_full.jpg[/image
EDIT:
got bored so i decided to start early, here is what i got so far.
1/19/06
First thing i did was remove the hood, then i put it up on jack stands, drained the oil and coolant.
Removed upper plenum, intake vacuume lines, wiring harness, Coil packs & wires
intake manifold, water pump pulley, alternator, & Electric fan
here is most of the parts that got removed, so far.
1/20/06
side shot of the 4.6 & 5.4 fuel rails
Top
if you look at the red circles (fuel perssure regulators, you will see that the 4.6 can be un bolted and replaced with a after market one, and the 5.4 has a inner snap ring that holdt it inplace. is there after marked fuel press. regulators for this one?)
the green are the quick connect fitings, they are on opposite sides so the fuel lines must be extended to reach. and yes you have to use the 5.4 fuel rail, i put the 4.6 rails on the 5.4 intake and they didn't fit that well... im sure you can make them go on but ill just use the 5.4 rail.
Stock NPI 4.6 intake manifold. has two coolant temp sensors.
5.4 PI intake with aluminum cross over.(only one temp sensor) the green circle on the left was a coolant nipple that went to the heater core. i din't know what it went to so i hacked it off, i milled it down and taped it so i can have both temp sensors in. but later i realized what it was for... the heater core
so i made this... this is going to go on the upper raidator hose and then the nipple will be ran back to the heater core.
1/21/06
a notch had to be cut so the oil pressure sender can be put on.
compairing the two Engines
compairing the two manifolds
these bottom two baffels need to be bent down 1/2 inch
my girl friend wanted me to, lol.
do this befor it goes in un like me so you dont have to pull it out them put it back in.
the passenger exhaust manifold has a casting lump that there is no need for so that had to be cut off for some clearance.
**Do this befor it goes in un like me so you dont have to pull it out them put it back in**
tilting the engine helps get it in/out
Makeing room for the intake so i had to mount the coil on the strut tower
... befor the motor is installed cut this are out, (where it is hammered) the EGR needs room so it is not on the fuel lines. and you also need to add 1 inch to the EGR tube right next to the EGR valve, you can strech/ and bend in the right places to make the 4.6 fit the 5.4. i used the 4.6 because there is no room for the 5.4 egr tube.
Whats that in the scoop?
Now dosn't that look AWSOME!
yes it dose hit on a 3" cowl hood with a SVO scoop. but only on the intake. it can move down
comming close...
oh and if you are going to do this and you have a PI mustang buy the addapter plates they are like $350 and you can use the stock 4.6 intake and notch your the under side of the hood but its not visable form the top. it will make every thing a LOT easyer, belive me. and the runners are shorter on the 4.6 so it will help make a little more hp then the 5.4 intake will. the 5.4 intake with loe longer runners will make more low RPM Torgue and less High RPM HP the 4.6 intake will do visa versa.( i would recommend the 4.6 with addapters)
1/23/06
Exhaust
ok so to make the exhauset fit... i cut the H in half so i can do one side at a time the Driver side fits perfect no modifications needed
Ther passenger side i either need to remove the lower stud to get it on, or can i cut the flange like this and then just bolt it on, im leaning to cutting the flange because it will be easyer then removing the stud if i have to take it out later.
[IMG]http://memimage.cardomain.net/member_images/12/web/456000-456999/456787_481_full.jpg[/image
01-19-2006, 07:55 PM
#3
4th Gear Member
Join Date: Aug 2004
Location: Philadelphia, PA
Posts: 1,654
RE: 96 GT NPI 4.6 to PI 5.4 Swap. (Pic) Starting on 1/21/06 Dark_Horse
Good luck. Hopefully everything will bolt right up. In any case, it'll be worth the work for the sound of the exhaust and the cool-factor.
01-20-2006, 04:57 AM
#8
3rd Gear Member
Thread Starter
Join Date: Oct 2005
Location:
Posts: 850
RE: 96 GT NPI 4.6 to PI 5.4 Swap. (Pic) Starting on 1/21/06 Dark_Horse
M1ke
what year and model does that motor come out of? i know some f150s have it but its kinda different or somethin idk
what year and model does that motor come out of? i know some f150s have it but its kinda different or somethin idk
