Gen 4 Duratec Intake

1540 Views 8 Replies 6 Participants Last post by Damon, May 11, 2004

NateNBeckie

Discussion Starter · May 5, 2004

This may be completely silly, but it was a thought I just had. Does anyone think there would be an advantage to swapping a Gen 3 Duratec aluminum intake manifold to the Gen 4 Duratec composite intake manifold? Would it fit without any modification? It looks like everything is pretty much in the same place.

Just an idea, call me an a$$ if you like.

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J Rod

· #2 · May 6, 2004

although this is a good idea there is more expense involved than just the intake.

maybe with a custom chip you would be okay

the vehicle will not idle very good with the secondaries missing and it is a dog and will backfire when it is not warmed up. I have experience because my IMRC actuator malfunctioned and stuck open.

with out the custom chip you would need a computer, throttle body, upper and lower intake, manifold gaskets, wiring harness, and MAF sensor. all from a gen IV.
there could be more parts but that is what i come up with.

Custom chip will by far be the most inexpensive way.

I have thought of it before.

benefits would be oval port design has larger openings than the aluminum,
plastic intake is lighter,
more low end torque if you ask me (i drove an 02 duratec and my car could not compare.)

parts that you will definatley need is
upper and lower intake manifold, and throttle body, and custom chip.

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mikehawk

· #3 · May 6, 2004

I think you also need to get a gen4 fuel rail if you're swapping the upper and lower plenums.

But, I don't think it would be that big of a deal just to swap the upper plenum. You'd have to make sure and get the gen4 EGR valve, and I'm not sure but you might need the IAC, too. What about the PCV ports? Are they the same with the gen3 and gen4?

BTW, I think the improved low-end torque came from the heads and the transmission (improved efficiency and better gears). Not 100%, though. The gen4 manifolds would help in the high RPMs though, no doubt about that. Really smooth all the way through, bigger ports, and no secondaries in the way.

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spridget

· #4 · May 6, 2004

I should be able to tell you in a few days. I have the aluminum intake off and a plastic intake is in the mail. As soon as it arrives, I'll test fit it and tell you what I find.

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NateNBeckie

Discussion Starter · #5 · May 6, 2004

Well, I didn't know that the gen 4 didn't have secondaries. I learned my 1 thing for the day, time to go home.

I can tell you that I don't like how the gen 4 runs compared to my gen 3. My dad had a 2002 Sable with the Duratec and I wasn't impressed. It was definately quieter and smoother but I hate that "cross-walk to cross-walk" delay in the power when you step on the gas. I have a 2002 MPV with the 3.0L DOHC (Duratec with a Mazda symbol on the intake) and it does the same thing. It drives me insane. I cured some of that by pulling the intake silencer off (Mazda had something even worse than the Taurus, but less restrictive). The other issue is the 5 speed AT they have mated to the motor. The shift points are screwy and it doesn't seem to utilize the power right. Sure does sound good without that silencer on though.

Spridget,

That would be cool if you could let us know. I hope it works well for you.

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3xtaurus

· #6 · May 10, 2004

One problem I have read about with the Taurus plastic manifold is that a backfire (a rare event) can shatter the manifold. Some pieces can end up in the engine, requiring a $$$ repair.

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Damon

· #7 · May 10, 2004

Originally posted by 3xtaurus@May 10 2004, 12:00 AM
One problem I have read about with the Taurus plastic manifold is that a backfire (a rare event) can shatter the manifold. Some pieces can end up in the engine, requiring a $$$ repair.

Yes. This was because ford issued a recall on the PCM and some of the recalls got screwed up, so they had another recall to correct this problem. At this time in point, its a rare thing to find, most of these problems have been corrected by now.

-DC

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spridget

· #8 · May 11, 2004

ok... the experiment is complete

The Gen 4 plastic upper intake does not work on the Gen 3.

The port sizes between the upper and lower intakes do not match, the throttle bodies are different, the EGR tube needs a little tweaking to fit, and the fuel pressure regulator mounts differently.

Anybody want a Gen 4 plastic upper intake? Come and take it.

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Damon

· #9 · May 11, 2004

Originally posted by spridget@May 11 2004, 05:19 PM
ok... the experiment is complete

The Gen 4 plastic upper intake does not work on the Gen 3.

The port sizes between the upper and lower intakes do not match, the throttle bodies are different, the EGR tube needs a little tweaking to fit, and the fuel pressure regulator mounts differently.

Anybody want a Gen 4 plastic upper intake? Come and take it.

Ill take it.

-DC

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