2.4L Log Intake Mod [Archive] - GrandAmGT.com Forum

SpyhunteR

02-02-2003, 04:19 PM

those links weren't working someone said.. so here's the guide...

2.3 intake manifold 'How To' Modifacation and Install Guide

___Parts to buy before hand___
2.3 intake gasket kit....... small tube of RTV (silicone sealer)

___Removal of stock parts___
Disconect the negative cable on the battery. Unplug all sensors and vacuum lines on the intake and t/b. Remove the throttle cables and bracket from the t/b. Remove the 4 t/b bolts and t/b and 7 intake manifold bolts and manifold. Remove the black tube that goes to your brake booster. You will be cutting this tube later. On the front of your trans, you will find a grounding stud, with wires and a nut on it. You will need to remove this, and relocate it down to the bolt below (I found this to be in the way on the 5 speeds, not sure on the auto) ***If you have a 96-99 (mid 99 they stopped useing the egr) you will have to remove your EGR and the mounting bracket. You will then need to install a exhaust gasket from a 99+ w/o EGR, in place of your exhaust manifold gasket, or make a block off plate for the front of your engine. Plug the wires back into the EGR, and zip tie it to the power steering lines just to the right of the engine.***

___2.3 Intake___
First things first, find yourself a good intake. The Log style is a good choice, and make sure its off a DOHC engine. There are a few part #'s for the H.O. ones, I have a few of the #'s: 22538691, 24570288, 24571319.

PICs>>>> (copy and paste)
http://us.f1.yahoofs.com/groups/g_2348233/Temp+pics/HO+vs+LO.jpg?bcw5QI.A_ckpJyhW

Modifying the intake. I used an extra 2.4 head to mark off the ports, but since most of you wont have this, you will need to use your 2.4 intake gasket. Its not easy, but you can mask of the parts you need to remove. Once you have the intake matched to the head, you now need to modify 4 bolt holes. The outer 2 and the center 1 line right up, its the 2 'Pairs' of bolt holes on either side of center that need to be modified. The bottom 2 need to be sloted out, the inner 2 need to be drilled lower, you will notice/see how far, once you try to line up the intake to the head. At this time, you should make sure you have a 2.3 intake gasket kit, and modify it to match your newly modified manifold. THOUROLY CLEAN THE INTAKE, REMOVE ALL METAL SHAVINGS!!!

PICs>>>> (copy and paste)
http://us.f1.yahoofs.com/groups/g_2348233/Temp+pics/AfterPorts.jpg?bcgBQI.AGmq2CQiP
http://us.f1.yahoofs.com/groups/g_2348233/Temp+pics/Finished_Flange1.jpg?bcgBQI.Acv2SEkVm
http://us.f1.yahoofs.com/groups/g_2348233/Temp+pics/AfterPort_Inside.jpg?bcgBQI.AmIp0MI4Y

Installing the intake..... Try to test fit the intake on the head, w/o a gasket for the moment. Make sure it fits, and nothing is in the way. If all is ok, remove the intake, install the gasket with a SMALL amount of silicone sealer, and reinstall the intake.

___Throttle Body___
Now for a t/b. You can use either a 2.3 56mm t/b, or a 2.4 t/b, either the stock 52mm, the Mantapart 56mm, the RSM 59mm or 62mm.

If you go with the 2.3 t/b, get a 93+ one, either with or with out the cruise option. Remove all the sensors, and be carefull with the bolts, since they are weak, and might break. You can use your 2.4 Idle Air Control sensor, just pull off the plunger on the 2.3 one, and swap it with the 2.4 one. For your Throttle Position Sensor, you need to use your 2.4 one, check your position of it on the 2.4, and place it on your 2.3 t/b. You will need to cut one of the mounting ears off, and drill a new hole in the t/b for the other one. Tap the hole, and mount the sensor.

PICs>>>> (copy and paste)
http://us.f1.yahoofs.com/groups/g_2348233/Temp+pics/TPS+Mod.jpg?bcgBQI.A31ZWk_gn
http://us.f1.yahoofs.com/groups/g_2348233/Temp+pics/TPS-Throttle+Body+Mod.jpg?bcgBQI.AQJhqRaLH

If you go with the 2.4 t/b, you dont need to mess with any sensors, use your stock ones. You will need to drill out the 2 holes that match up with the holes in the intake. Just select a drill bit that is slightly larger then the bolts. To mount the throttle cable bracket, I would first get one off a '95 2.3(part # 22590179), just because it was made to fit in the J-body with this intake manifold. The upper bolt hole in the t/b will need to be taped, to bolt the upper part of the bracket in place.

PICs>>>> (copy and paste)
***Pics comming soon***

Either way you will need a 2.3 intake gasket kit from any parts store, in the kit you should get a t/b gasket. Use a SMALL amount of silicone sealer, and mount the t/b gasket and t/b to the intake.

___Rewiring and plumbing Vacuum lines___
You will have to remove some electricle tap, and open the loom slightly. You SHOULD NOT NEED TO CUT ANY WIRES!!! Run your Cam Position sensor plug behind your intake, between the runners, and plug it in. Pull the rest of the wires to the t/b. Plug in your IAC and TPS. I mounted the MAP sensor onto the intake by the power steering pump. I ran the vacuum for it to the port on the back side of the intake. The vacuum line for the FPR goes to the first port on the left of the intake. There is a vacuum line that comes up from underneath (just behind the A/C compressor) rout that one to the center vacuum port. The large hole in the front can be pluged with a common pipe plug found at a hardware store. There should be one small vacuum line and the large tube from the brake booster left. The small one is for you HVAC controls, mount that to your t/b. The black tube from the booster needs to be cut, you will need a peice long enough to reach the rubber hose that plugs right into the booster itself. Should be about 6-8" long. Remove the rubber elbo from the rest of the tube, and install it onto the large opening on the t/b. This leaves you 2 ports on the t/b that need to be plugged, you can pick up vacuum caps from a auto place, or just run a small peice of tube from one to the other. Now is the time to connect your throttle cables. Connect them the same way you took them off your t/b. If you have cruise, GM makes a part to turn your cruise box over (part# ***Comming soon, its from the GM supercharger kit***)

___EGR___
We removed the egr and mounting bracket from the head, kept the egr plugged into the wire harness, and ran a vacuum line from the intake manifold (any port but FROM THE MAP SENSOR) to the large open port on the egr. We used a brass nipple fitting and a filtered air line fitting (3/8 pipe thread), and tapped the large egr port with a 3/8 NPT tap. No check engine light. Then just zip tie the egr out of harms way.

PICs>>>> (copy and paste)
***Pics comming soon***

___Intake and filter___
You can use your stock 'S' tube with a cone filter to the stock location, or you can cut the tube, and run the filter straight down...... or make up your own combo.....

PICs>>>> (copy and paste)
http://us.f1.yahoofs.com/groups/g_2348233/Temp+pics/Changeforabutton_2.jpg?bcgBQI.AwJawvxbK
http://us.f1.yahoofs.com/groups/g_2348233/Temp+pics/Tenacious+Z+2.3+HO+Intake.jpg?bcw5QI.AKEbbrYrm
http://us.f1.yahoofs.com/groups/g_2348233/Temp+pics/2.3+HO+intake+on+2.4.jpg?bcw5QI.AMLjQkFGH
http://us.f1.yahoofs.com/groups/g_2348233/Temp+pics/2.3+HO+intake+on+Turbo+2.4.jpg?bcw5QI.AsiKW1B0M

That is it, you should now be able to reconnect the negative cable, and start your baby up. At start up, it will Idle about 2000-3500 rpm, till the IAC valve resets.... if it goes any higher, or doesnt come down after 30 secs. you have a vacuum leak. To check for a leak, listen for a whistle, or just shut it off, and check your gaskets. If everything is ok, let it idle for 5-10 mins to let everthing reset. If you get a SES light, take it into any AutoZone and get it checked. Make sure you get the code # and what it is.

If you need any help, email me at wizzer03@hotmail.com

Enjoy

Brian
Speed Racer Z