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Author Topic: Bullet Intake Install in an MN12!  (Read 2438 times)

J dot Miller

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Bullet Intake Install in an MN12!
« on: November 19, 2006, 06:43:52 AM »
A few months I  :miller: and :freddie: made a custom 5.4L Bullet intake..  This is how I installed it.  This tech should apply to most 4.6L Thunderbirds and Cougars...  I have an 1995 intake with 1997 wiring...

To do a job like this I decided to get help from the best.  So I drove up to Connecticut to visit my long time pal Jeff Tatro.  Jeff's garage is a little small so we need to find another place...



Here is Jeff...  Yea he is a redneck...


You can tell by his truck...


A redneck can't do a thing without coffee!


We too the Cougar here...  Much more room than that tiny garage...


Of course, to do the job right you need some tools...


And more tools...


and the drawers are NOT empty...









Time to lay out my parts...


Now time to get to WORK!  Disconnect the battery and drain the antifreeze...



Attach the redneck hood light:


Now I can see...


Remove the belt and old intake tube...  Throttle & cruse cables...


Remove the radiator hoses...


Install a redneck fender cover...


Disconnect the wiring loom behind the shock tower...




Fold the harness over to the right...



Mark the plug wires...


And remove them...


Disconnect the fuel rail connectors from the fuel line and bend them so they do not leak...


Remove the fuel rail...


A distraction...  SWEET!


Remove the elbow!




Bye bye old intake!



Since I am putting in a custom built 5.4L intake things get a little trick so a test fit is required...



If this was a 4.6L you would not need to do the following but my intake did not fit.  See those while lines.  We are going to have to grind a little between them...



Now she fits...


The trim needs to be adjusted because the elbow will not fit...



Now she fits...


Now we have to remove the intake and relocated the DPFE (differential pressure feedback EGR) and the EVR (EGR vacuum regulator) sensors.



The EVR goes on the Right...



A few spare vacuum hoses will help things out...


There we go...


The DPFE goes on the left...


As you can see the old 1995 style EGR tube ends here and the DPFE lines can easily be connected.  WARNING:  Only use high temperature silicone hose here!


Time to trim off the EGR tube...


The natives are restless...


Jeff says lets get some ribs and beer!


« Last Edit: November 19, 2006, 06:46:36 AM by J.Miller »
The 5.4 swap has been called a bad idea, and considered an underpowered considerable waste of time, since 2007.

Nice to see that most donít think that anymore.
Bondfreak13 07/28/09 09:05 PM

J dot Miller

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Re: Bullet Intake Install in an MN12!
« Reply #1 on: November 19, 2006, 06:44:21 AM »
We had a little trouble with the EGR tube on day one.  We tried to hard pipe it but it was difficult to adjust for the right connection into the EGR valve.  It would not have been difficult if I had a tube bender but someone left it at home....

So we ended up with two short silicone hoses and two spool pieces.  I would be hesitant of the large hose but at this location the EGR tube is long so we expect it to be cooler.  Besides the actual hose exposed to heat is less than 1/2" long.


Now the intake is fitted we install the bottom plenium cover...



Install the fuel rails.


Now time to prep the engine!



While Jeff was playing with the intake I assembled the upper plenum.


When we installed the engine back in 99 the old intake had some scratches so we do not take any chances and apply copious amounts of high temp gasket sealer to the heads....



Time to install the intake...


The 1996/ 1997 fuel rails had to be bent to fit...


We pilled back the wiring harness...


Reconnect the alternator...


The 1997 TPS sensor wiring did not fit.  Luckily I had a spare 1997 ACT sensor & associated pig tails!


So we installed the 1995 ACT and pig tail to the wiring harness to replace the 97 ACT wiring.  The we modified the 1997 pigtail and 99 bullet throttle body so that the 97 pig tail fit.






The ECT sensor wiring was a little short and had to be extended...



The belt was installed...


A little wiring clean up was at hand...



Now we can install the upper plenum.



Perfect fit for the EGR!


A little oil and antifreeze and 50/50 mix was at hand and ready to go in the car...


We connect the harness behind the strut towers!


Install the fuel rails...    It was a scary moment because we had to bend the 97 tubes around for the right fit.  We were afraid that the tube would break.  Luck was on our side today!


The coolant connection in the back of the intake is installed...


Oh oh!  We have interference.  The C&L inlet pipe refused to fit!  There was only one choice and that is to modify the shock tower!



Thats better...  At least for now!


I brought a bunch of vacuum lines with me.  They came in handy...



We were getting tired so we installed the old 97 throttle cable...



The air filter is now installed...


The hood would not close so it was pulled off and I planned to drive home without a hood...


She fired up on the first try...

The 5.4 swap has been called a bad idea, and considered an underpowered considerable waste of time, since 2007.

Nice to see that most donít think that anymore.
Bondfreak13 07/28/09 09:05 PM