Finally got around to finishing my composite upper intake manifold swap. Finished the EGR delete last weekend, drove it about 200 miles like that and finished the swap today. I used a 02' UIM, 05' Ranger 3.0 TB, 02' Passenger Side valve cover and intake tube. Trucks not done learning yet and needs a tune to properly delete the EGR. Also need to buy new plug wires and coil pack so everything looks proper with the newer valve cover--the coil pack mounts directly to the valve cover. The IAT sensor was relocated to the airbox on the clean side of the filter, the stock 99' throttle cable was retained, and all the vacuum lines needs were taken care of easily by moving a few lines/fittings around. I still have 3 vacuum lines, several fittings, etc left over due to the EGR delete. The wires for the TPS and IAC were long enough, I only had to extend the wires for the IAT as the newer intake tube doesn't have a fitting for the IAT--hence the airbox location.

I've only got about 10 miles on it at this point and the truck feels MUCH stronger in the lower RPM's. From idle to 2600 rpm the difference is tremendous, 2600-4800 it feels the same, above 4800 (only took it to 5300) it feels better--move over-rev. The torque curve is flat, it doesn't feel peaky like it did with the aluminum upper.

I'll drive it more tomorrow and take a bunch of pictures and post em' up.

 

Here are some pictures.

Overall shot.


Driver side. I was able to use the 3-outlet 90 degree elbow out of the back of the aluminum manifold on the composite. The only vacuum line at the back of the engine is the PCV valve. Engine looks much cleaner without all the EGR b.s.


Passenger side. New valve cover, coil pack in it's new home. Upper left show the main harness, I modified the bracket and attached it to the firewall w/a wiper motor bolt since the intake doesn't have a bolt provision on the back.


Closer view of it all.


New IAT location.


All the wiring moved and relocated.




All in all I think it turned out well, I'm very happy with how it looks and performs.

 

Sorry about the picture quality, my camera sucks.

 

ok...i see...sweet!

 

Hmm... no EGR? Sounds like a good mod.

How much do you figure this whole set up would run, not including a programmer?

 

I've got about $200 into the swap so far not counting any returns I'll get out of my old parts. However, I know the 96's have a different UIM so I don't know if more would have to be changed or what would be involved. There's enough similarities between the 98-01 3.0's and 02-up to somewhat simplify the swap, I'm not familiar with pre 98 3.0's.

 

Put about 40 more miles on the truck today and I'm still impressed with the low end torque improvement and overall improvement of driveability. It's not a torque monster by any means (I drive a modified 5.0 fox Mustang 5spd w/3.27's as well, so I know torque), but any small improvement in low end torque on these little 3.0's is very welcome.


EDIT: Some of the 'spackle' seen on the passenger side of the engine compartment is not from an oil leak, it was my fault. Some dirt fell on the rockers when I was changing the valve cover. I blew the dirt off with 120psi and made a helluva mess.

 

Went on a 360 mile trip today and got a good highway test with the new intake. Much less downshifting to 4th to climb steeper hills, much less throttle needed to maintain freeway speeds and a much better driving experience overall with the added low end torque. I'm really surprised with the added revs on top of the rpm range, the wider power band is great. Fuel economy is better as well. Truck averaged just over 23mpg driving at 70-75mph most of the trip. The drive was over several mountain passes, on flatter ground I think 25mpg would be easily attainable--not bad for a ex-cab 4x4.

 

Installed an 01' 3-bolt coil pack today, the pack that had been on my truck since I bought it fell within the number range shown on a TSB so that gave me a good excuse to justify the cost. Had to cut off the old coil pack plug and splice the newer style in place. Also installed new Motorcraft plug wires for an 02-03 Ranger and got rid of the POS Taylors that I put on it a couple years ago.

The Motorcraft wires are less money, fit 10x better and last longer than the Taylors. One of the wires on the Taylors failed within 15k miles.