PI Intake Manifold w/ PI Head Swap Overview - Tech Article

What is it that changes when upgrading from the 1996-1998 NPI heads and intake to the 1999-2004 Mustang GT’s PI heads and intake that makes the swap so complicated? The NPI heads that came stock on all 96-98 GT’s use a different internal design therefore creating the need for a new intake manifold. When you are upgrading your intake and your heads you’ll also need to pick up some additional parts depending on your year.

New Hoses: The difference in design causes issues with hose and bracket location’s on 1996-2000’s. The new intake manifold has a longer aluminum reinforced runner that extends the hook up to the thermostat housing. This requires the need for a new hose kit like that on the 99-04 GT.

New Brackets: If you own a 96-00, you will also need a new alternator bracket from 01-04 GT to relocate it. This bracket makes install easy allowing all your hoses to fit properly and relocates the alternator for proper thermostat fitment.

What about PI Heads? The 99-04 GT came stock with this higher compression, cooler running PI head. The 01-04 GT also came stock with the aluminum reinforced intake manifold and together they produce nearly 40 more HP compared to NPI set ups.

PI Intake Manifold

Materials needed for use of PI Intake Manifold PI head swap on a 1996-1998 Mustang GT:

  • PI Intake Manifold
  • PI Heads
  • Heater/Coolant hoses from 99-04 GT
  • Alternator Bracket from 01-04
  • Gasket Set for PI heads
  • Intake gasket
  • Thermostat gasket
  • Fresh coolant

Avg. 6-8 hour job w/head swap Avg. 1.5-2 hours w/out head swap

Materials Needed for PI intake manifold on PI head equipped car or stock 99-04 GT

  • PI Intake Manifold
  • Alternator bracket 99-00 only
  • Gasket Set for Intake
  • Gasket set for thermostat
  • Fresh coolant

Avg. 6-8 hour job w/head swap Avg. 1.5-2 hours w/out head swap