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The marine dual plane aluminum intake install.
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A few months ago I came across an all aluminum version of a marine intake for the Vortec engines. Figured it is about time to make a thread about it.

I have a 2002 S-10 with a 1996 Vortec 5.7/350. I have ran into trouble after trouble with trying to fix a missfire at idle, only to find out my lower intake manifold is warped causing a big vacuum leak. Its about time I install this new intake.


Here is what I found at a local marine shop:




When I first saw this it left me scratching my head. Noone had ever posted about this intake. Just the cast iron one. Well, take a closer look...















I said to myself well I'll be damned....thats a dual plane fuel injected all aluminum Vortec intake!!!!!

How bout a full length how-to-install write up? Well, I am doing that right now.

Now, one disclaimer. You cannot use EGR with this intake. This is not a big deal to me because my truck is a 2002 and did not have EGR to begin with.

Here is a parts breakdown of everything you see here...

http://www.perfprotech.com/mercruiser-parts-finder/throttle-body-and-flame-arrestor/assembly/4848/110?model=947

http://www.perfprotech.com/mercruiser-parts-finder/intake-manifold-and-fuel-rails/assembly/4848/120?model=947


The injectors that come in this setup are 36 lb/hr. The fuel rails are big and beefy. The crossover tubes are setup that way because the marine engine is a returnless fuel system. No need for those on our engines, a single tube will do. You will have to run an external adjustable fuel pressure regulator.




More to come.....oh...BTW.....I know where a few more of these intakes are if someone wants em....



Last edited by lwrs10 on Mon Jun 24, 2013 7:12 pm; edited 5 times in total
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Here she is all cleaned up and ready for install...





Now to add the thermostat bypass hose to this there are 2 options. You can use the 1/2NPT spot to the right of the thermostat, but then your A/C compressor wont fit. So I drilled and tapped a hole under the thermostat for it.




The throttle body adapter all cleaned up....





Last edited by lwrs10 on Fri Jun 14, 2013 7:47 pm; edited 1 time in total
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here is my engine.....just started tearing it down for a slight miss at idle on cyl 3....found a burnt valve, and a blown head gasket.

How it looked before teardown....



stupid broken intake bolt.....



Had some moisture in here.....there is rust everywhere...



Where I thought I was going to stop....by this guy Murphys law stopped by....








Last edited by lwrs10 on Tue Jun 18, 2013 5:42 pm; edited 1 time in total
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a small update while I wait on the machine shop and parts.

Tonight I tackled the throttle body swap over. The marine one will not work with the marine shaft, so some modifications were made.

First, the size difference between the 5.7 truck and the 5.7 marine throttle body.

You can see how much bigger the marine one is on the left. I measured 6mm bigger, which is quite a bit.




The 5.7 blade in the back of he marine body



The 5.7 blade in the back of the truck body



Truck body measures 70mm



Marine one measures 76mm



Marine blade on left, truck on right.



The bodys, besides the size difference and the taller top on the marine one(this is very desirable for the boosted guys), are the same. Same bolt pattern, same sensors, etc.



The marine one has an AC Delco part number. Can anyone dig these up?



You have to change the shaft to the 5.7 one. The throttle hookups are totally different, and no spot to hook up the cruise control on the marine. You simply take off the TPS sensor and lightly tap out the shaft. Use extreme caution because there is a metal washer that holds it all together that you have to re-use.

Here is that washer



Swap the throttle shafts, and reuse that washer. Very lightly and paying extra attention, tap that puppy back on the shaft once you swap them. If you break it you cannot get another one.



Even though the TPS and the IAC were the same part number, I swapped them with the truck ones anyway.



Here it is assembled and ready to go!






The mounting bolts are different on the marine adapter. You will have to change them. I will be using a small piece of all thread since the marine threads are not metric.

Here is a pic of the bolts side by side. Marine on the left, truck on the right.



You have to have the stand offs on the back of the bolts to attach the throttle brackets. Thats why I think a short piece of all thread will work great. I will post pics once I get that part figured out.



Last edited by lwrs10 on Mon Jun 24, 2013 7:02 pm; edited 1 time in total
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Very nice. Really like the adapter

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Very nice

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Very interesting. Who made the intake manifold?

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Chevy 97 wrote:
Very interesting. Who made the intake manifold?


It's a mercruiser

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Very nice! How did you get it so clean?

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Probably a sandblaster

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daddy_dandy wrote:
Probably a sandblaster


Yep.

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That Adapter would be nice to clone.

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How well will that dual plane perform on the truck motor?

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Chevy 97 wrote:
That Adapter would be nice to clone.



i bet i know a place that can make then with a CNC machine out of aluminum.

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updated!

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Make mold!
Make mold!

Inject phenolic

Sell to me.

Sell to ebay!

Make the money!

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CrazyHoe wrote:
Make mold!
Make mold!

Inject phenolic

Sell to me.

Sell to ebay!

Make the money!


That was my thinking. Someone else on here Showed me a picture of the one he had CNC machined. I cannot find that thread. then you could bolt it to Edelbrock or Holley intake designed for MPFI.

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I have an EFI Holley square bore intake that could use that adaptor.

I'm just going to drill a flat plate for now.

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http://www.pacificp.com/forum/viewtopic.php?t=5295&postdays=0&postorder=asc&highlight=adaptor&start=0

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thread updated!

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