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| The
Explorer lower intake (right) is the same piece as the Cobra
and GT40 lower, sharing the staggered round runners. Due to
their inline configuration, the stock runners have smaller
cross-sections, and move less volume. |
Only 1995-1996 Explorer intakes have EGR passages, so keep
this in mind if you need to pass smog requirements. |
The
throttle body opening on the Explorer upper measures nearly
65mm in diameter, whereas the stock intake is about 60mm.
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| Another
view of the throttle body openings on both the stock and Explorer
intakes. Also notice the oval EGR hole below the throttle
body opening. Later Explorer intakes do not have this. |
The
stock studs, throttle body and EGR spacer transfer right over.
Explorers came with a 65mm throttle body which can be made
to work with some modifications to the throttle plate linkage. |
The
vacuum line configuration is slightly different under the
Explorer intake. We had to cap a couple extra ports, and lengthen
one vacuum hose in the engine compartment. It's all self explanatory
when you get the intake on the motor. |
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| Explorer
lowers do not come with pre-drilled holes for the ACT sensor
or the EGR coolant return hose fitting. The ACT sensor can
be drilled with a 37/64" drill, and tapped with a 3/8-18
NPT tap. |
The
arrow shows where we drilled and tapped for the EGR coolant
return fitting. We simply took the stock fitting to the hardware
store and matched it to the correct tap size. |
The
ACT sensor is transferred over from the stock intake to the
Explorer lower. |
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| Before
permanently bolting down the lower intake, we wanted to check
for port alignment between the intake and heads. This can
be done two ways, you can use a coat hanger or stiff wire
with a little hook on the end and simple feel for any mismatch
between the roof, floor, and walls. The other way is to mark
the position of the intake relative to the head, as shown
here... |
...then
measure the distance from the mark to the edge of the port
on the head. Also measure the intake in the same way. These
distances should be equal. If they are not, you can correct
the problem by either milling whichever component is sitting
higher, or by slightly porting the component that is sitting
lower. The Explorer intake and Holley head mated up perfectly. |
The
Fel Pro 1250 intake gaskets were set in place, using a light
bead of RTV sealer between the gasket and water passages.
Always use a thick bead of silicone rather than the cork end
seals. |
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| Other
than drilling for the two holes, the Explorer lower is a direct
bolt on. The stock 5.0 injectors and rails bolt right up. |
The
upper intake is set into place. We needed to make a trip to
the hardware store to get two longer bolts for each end of
the intake. We also had to lengthen the vacuum hose from the
charcoal canister, and connect the EGR pressure sensor vacuum
line using a "t" connector. |
The
Explorer intake looks like a hybrid between a GT40 upper and
Cobra lower. The increased plenum volume should meet the air
demands of the better breathing Holley heads. |
