This page is dedicated to my Explorer intake install. A lot of people have had questions about it and I hope to give a basic over view of how the install is done and what problems you might run into. If you are a newbi like me to this plan for at least 2 days for the install. It helps to have someone around who has done an upper/lower swap so you can ask questions.
1.Power Wash you motor then Strip off
every thing except the Thermostat from the package you receive( the parts you
cant use with out heavy modifications are - The wiring
harness, 19lbs injectors, Fuel Rails, and 65mm TB Elbow)
2.Unbolt the Upper from the lower
3.Now its time to plan at least a day for the install
4.Disconnect all the wires from you distributor. Mark where the rotor is
and what position the Distributor is facing.
5.Now remove the Distributor
6.Disconnect Everything from your
current upper ( you can leave the wiring harness in the car)
7.Once you have your upper out unbolt your TB and place it one the side
8.Now disconnect everything from your lower and unbolt it
9.Now disconnect your fuel lines (remember you need a special
tool for this) and bleed out any pressure that is in them. (have a coffee can
handy)
The above steps sound easy right, Well they are not. IF your car is anything like mine every thing is brittle and all the connectors are a pain in the but to get apart. Needless to say a few got the locking snaps broken off. In the pic above you notice that the Explorer intake does not have the same EGR system as the stock lower. The stock lower has the hole in-between the ports. Explorer lower does not. The Explorer did have an EGR system with the package. I am sure that you could modify it to work on the mustang. I chose not to. SO I have an EGR less car. Not a problem. No check engine light and I run a 2.5 off road pipe. Inspection might be a problem but I am sure I can get it threw with out the EGR system hooked up.
10.
OK now to get dirty. Fill the Valley (once you get it off you see why they cal
it that) with newspaper. Also fill all the ports with newspaper.
11. Scrape off all the
old gasket till you see bare metal.
12. Vacuum everything
including the newspaper when you are done.
13. Now
Remove the newspaper gently and Take paper towels and sop up everything in the
Valley
14. Now remove
you fuel rails from your old lower. If you unbolt the rails the injectors come
right out. The rails are the only things holding them in.
15. Drill
the hole in the Explorer lower for the air temp sensor. Mine was marked but if
not just look at you old lower and drill in the same
place. Then Tap the hole to the proper size.
16.
Install the injectors and fuel rails into the Explorer intake. Again the
injectors just pop right in.
17.
Screw in the air temp sensor
From here on in its easy
18. Clean the lower intake bolt holes by running a tap threw them. Make sure you are cleaning them and not cutting new metal. You can tell by the
way it fells
19. Now place the gaskets on. Be careful with the front and back lower intake gaskets. My kit was from Ford and they leaked. Some people just
put a whole bunch of Black PCV there and wait till it gets tacky before installing the lower.
Now go in reverse of taking your old
lower off
20. Install lower and Torque
the bolts down
21. Reconnect all the fuel
lines and other hoses
22.Retourque the lower
23.Now Install the upper
24. Some of the vacuum lines on the Explorer are in the
front where they where in the back on the stock upper. So have some extra vacuum
line ready to run. Its not a big deal
believe me.
25. One vacuum line in front of the Explorer intake
needs to be plugged. It’s the one in front on top of the rest. (once you look
at it you will know)
26. Bolt back on the TB and reconnect the Throttle cable
Now you are done and it should look like this!! Take it easy on the motor for about a day you don't want to Blow out the lower gaskets. If you have any questions just ask in the SSOTN basic tech forum.