Repair after Repair

KasperBPMC · Aug 6, 2022

Alrighty, so i got the dreaded cracked intake at the back cooling port. After reading a ton of posts, i got a replacement manifold from doorman. While i was in it, i replaced all the hoses including the bypass, for good measure. From the intake coming off, i got some water mixed with gas in some of the runners. I blew as much out with compressed air as i could. I also had to clean out tons of muck in the plug holes. So i got the plugs pulled out, i ran a stainless steel brush through the holes, blew it out with compressed air. After getting it all assembled, i turned it over with no plugs installed to clear crap out. As soon as i got it running, a quick squirt of crap out the tailpipe. I get it running, get it full of water. I take it for a test drive, i am getting a chug, i got no codes, watching 10 miles of live data on my scanner, only code is dtc. I cram on the gas, its responsive, but still a chug on lower rpms. I sorta think my cats may be clogged. I am going to give it a smoke test, there are always questionable vacuum lines on these cars. Since i am running extended antique plates on my car, i am exempt from emissions, if i have to pull the pipe, anyone got a part number or know anyone with an offroad hpipe for a 97 4.6 car?

07GtS197 · Aug 6, 2022

If you have a vacuum gauge you’ll be able to tell if it’s plugged cats that way. Last time I checked summit still had some off road midpipes but that was some six months ago. Used will probably be the way to go.

lwarrior1016 · Aug 6, 2022

Man, dorman really stepped up their game with the npi intakes. When you were in there, did you put new spark plugs in it?

KasperBPMC · Aug 6, 2022

lwarrior1016 said:
Man, dorman really stepped up their game with the npi intakes. When you were in there, did you put new spark plugs in it?

I prob read 50 posts saying that when doorman first made them, they were garbage. I did replace the plugs. My dad just pointed out that my feeler gauge was at .041 not .051. I feel like a stoonad. I am letting it cool down and i will pull the plugs and gap them right and see if its still doing it

KasperBPMC · Aug 6, 2022

And the bonehead award of the year goes to, myself.. i gapped the plugs at .041 not .052-.059. I thought i had .030 and .021 stacked together. I am 45 and my dad still loves to say i told you so

lwarrior1016 · Aug 6, 2022

KasperBPMC said:
View attachment 19303
And the bonehead award of the year goes to, myself.. i gapped the plugs at .041 not .052-.059. I thought i had .030 and .021 stacked together. I am 45 and my dad still loves to say i told you so

It’s all good, mistakes are made all the time. The PI dorman intake is still trash. It robs power and it uses all self tapping hardware for the fuel rails and whatnot. Your intake has thread inserts and looks like it uses stock hardware, that’s a huge plus.