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#4070824 - 07/15/20 10:04 PM 1994 intake on a 2000 grand marquis
tucker117 Offline
Stranger

Registered: 07/10/20
Posts: 7
Loc: Ohio
Hello every one! Im matt, I am new here. I currently own a 2000 grand-marquis with the npi 4.6. Bone stock and has 320k miles on her when the odometer stopped working. The only thing I have done is replace the intake with a improved aluminium crossover one back in 2012.

However the "improved" dorman intake cracked behind the #5 cylinder and created a mess.

I was at the junkyard today getting parts for my blazer and found a 1994 and a 1996 crown vic with the 4.6 however I noticed they had solid aluminum intakes. However the tb and related goodies hookup to the back. Would it be possible to modify my car to take the aluminum intake? My understanding is that I need to modify the egr tube, throttle cables, iac, and the altenator brackets? I can fabricate a air tube and reuse the maf.

I was also thinking about fabricating using a metal 3d printer a tube that would go from the current spot the intake plenum throttle assembly is to the hole on the solid aluminum intake so i wouldn't have to modify much?

Thank you in advance for any and all input.
_________________________
2000 2v 4.6 340kish miles in a 2001 body.
Had her since new then the frame rusted in two, put the engine in a donor car.

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#4070828 - 07/15/20 11:58 PM Re: 1994 intake on a 2000 grand marquis [Re: tucker117]
Bellwestern80 Offline

Tired All The Time
Over the Hill

Registered: 07/01/11
Posts: 3840
Loc: Evans, Georgia
I'd not suggest using the early intake. The EGR passage on those are prone to getting stopped and need normal cleaning. Also, it's a bit more restrictive than the '96+ intake design.

Best option is honestly to use a Ford intake over the Dorman ones. You can actually use the PI one if you follow the existing directions on how to adapt it to the nPI engine. Otherwise, if you poke around you can get a nPI Ford intake.
_________________________

My Cars:
-1987 Mercury Colony Park LS (330K Miles | H.O. 302) - March 2017 POTM Winner & November 2019 POTM Winner
-1997 Grand Marquis LS (222K Miles | nPI 4.6) - The Daily Workhorse & April 2013 POTM Winner

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#4070834 - 07/16/20 10:35 AM Re: 1994 intake on a 2000 grand marquis [Re: Bellwestern80]
BigMerc96 Offline

I know nothing
Posting Addict

Registered: 06/05/10
Posts: 19861
Loc: I can see Detroit from here!
Originally Posted By Bellwestern80
I'd not suggest using the early intake. The EGR passage on those are prone to getting stopped and need normal cleaning. Also, it's a bit more restrictive than the '96+ intake design.

Best option is honestly to use a Ford intake over the Dorman ones. You can actually use the PI one if you follow the existing directions on how to adapt it to the nPI engine. Otherwise, if you poke around you can get a nPI Ford intake.
100% agreed. It is much less work to use a PI intake on it than to try and downgrade it to the earlier and more restrictive and somewhat problematic aluminum intake. To run the later PI intake all you really need is to put a bead of RTV around the coolant ports on the heads to make up for the gasket mismatch (which is only slight around the coolant ports). That and swap in the '01+ style under-intake bypass pipe, which isn't a bad thing anyway since an Aero uses that funky one with the short bit of hose behind the waterpump that's prone to failing due to age. I'd replace that bypass tube either way since its 100x easier when the intake is off. I did a PI intake on my '98 last year, and I'll be doing my co-worker's '98 here soon because its original intake is starting to leak.
_________________________
-Steve

2006 Audi A6 ~132k miles, stock.
1998 Mercury Grand Marquis LS HPP ~100k miles, slowly acquiring modifications.
1997 Town Car Cartier ~145k miles, Ported Plenum, Gutted Airbox, Contour E-fan Retrofit, Dual exhaust with Magnaflows, cats deleted, MSD Ignition, KYB Gas-A-Justs, P71 front bar, air ride reinstated, Projector retrofit, Caddy 4-note horn retrofit, Wood rim steering wheel retrofit, holistic weight reduction as the parts fall off..
1996 Mercury Grand Marquis GS 117,485mi. R.I.P. 7/14/12 frown

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#4071098 - 07/18/20 09:57 PM Re: 1994 intake on a 2000 grand marquis [Re: BigMerc96]
tucker117 Offline
Stranger

Registered: 07/10/20
Posts: 7
Loc: Ohio
Thank you for your suggestions!

I just finished the Pi intake swap. Car runs fine other than at idle has a slight miss like its choked out. Sorta like a lawnmower that is on choke when its running. However when i giver her gas she runs great.

I think its the IAC valve. With the intake off I replaced the coils, plugs, MAF, thermostat, egr, and air filter. Its the only thing on the top end of the car that still stock and with 300k miles on it. I pulled the plug off of the Iac and there was a small change to the engine then it died a half minute later

Should if i need to replace it get a new part or go to the junkyard?

respectfully,
matt
_________________________
2000 2v 4.6 340kish miles in a 2001 body.
Had her since new then the frame rusted in two, put the engine in a donor car.

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#4071106 - 07/18/20 10:44 PM Re: 1994 intake on a 2000 grand marquis [Re: tucker117]
ClayBelt Offline

Over the Hill

Registered: 04/03/18
Posts: 1542
Loc: Leon County
Just spray it out with some brake clean. Will do a good enough job unsticking it
_________________________
There’s a right way, a wrong way, and a janky way to fix something; I don’t usually have the brains or the money to pick the right way.

2001 Chevrolet Tracker LT “Featherbrick” - 6/2016-10/2016 - SOLD
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1966 Ford Thunderbird “Fordy McFordface” - 11/2016-2/2020 - SOLD
2005 Buick LaCrosse CXS “Jumba” - 2/2017-2/2018 - SOLD
2010 Mercury Grand Marquis LS “Touge Sofa” - 4/2018-?
1990 Mazda Miata “Little Boy” - 5/2019-10/2019 - SOLD
1986 Ford Mustang SVO “Touge Fox” - 2/2020-?

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#4071128 - 07/19/20 12:38 AM Re: 1994 intake on a 2000 grand marquis [Re: tucker117]
RF_Overlord Offline

Poobah

Registered: 12/14/02
Posts: 7227
Loc: MA
If you end up replacing it, get a Motorcraft or a Hitachi only. (Hitachi makes the OEM part for Ford) Aftermarket IACs seem to fail prematurely.
_________________________
'03 Mercury Marauder (The Blackbird)
Trilogy Motorsports supercharged #61
Too many mods to list / Driveway Queen

'04 Grand Marquis LS Limited Edition (Spruce Green)
Daily Driver (Thanks, Adam!)

'00 Grand Marquis GS (Silver)
Rotted frame and broken transmission crossmember
Being resurrected...slowly.

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