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Discussion Starter · #1 ·
Today I finished up my cowl intake to replace my K&N FIPK "cold air intake"

I decided to go with the Ford Windstar/Ranger route, here you can see it together.

The box is from a 4.0L Ranger out at my local junk yard, I shortened the back half of it that would normally contain a mass air flow sensor.


I just used some industrial strength super glue, a little plastic weld, and some permatex black silicone to seal up the chopped up back.

The 90 is something I found on amazon 4" to 3" reducer
http://www.amazon.com/gp/product/B00CB2353O/ref=oh_details_o00_s00_i00?ie=UTF8&psc=1
By far the most expensive part of the build.

The rest of the intake is from the stock intake, Luckily I got the intake hose in a box-o-parts from the previous owner.




With the intake together I just took a good ole fashioned hole saw to the cowl, which was very nerve racking....


After cutting the first hole and seeing how the ford rubber head fit, I ended up drilling a second smaller hole and used a PCV Grommet to fill it. just for a little extra drainage in off chance I have water coming over the hood.


Being the paranoid type I also made a small flap for the cowl and plasti-welded it to the inside.

On the 97 Wrangler the cowl has 3 air inputs, the two outer inlets are mostly blocked off, I glued this flap to the passenger side just as a little extra rain proofing for the intake.

The whole intake went in really nicely. Only took me about half hour once I had all the pieces.
 

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Discussion Starter · #2 · (Edited)
I didn't really do this with performance in mind, I really just wanted replace the K&N and open up some space for my OBA build but...

Here are The Results:
via ECU reading and the use of the android Torque Pro app

K&N:
average intake temp 180 degrees, average intake pressure 5.5psi

Fresh Air:
average intake temp 70 degrees, average intake pressure 7.8psi

I have been keeping a strict eye on the intake temp and even with it getting colder out it never seemed to be much more than 20 degrees cooler than the engine. I was expecting the new intake would be somewhat cooler but was not expecting it to be THAT much cooler. The extra PSI was a complete surprise, especially since I am just running a STP paper filter in the new setup.

I was driving around most of the day today, both highway and in town. Highway it stayed closer to 60 degrees and it never went much higher than 70 even in stop and go in town traffic. The warmest it got was 91 when I let it sit idling for 15 min, and within 3 min of moving it was right back down to 65-70 again.

Im sure it will warm up some in the summer when its hot out but its SO dramatically cooler I can be nothing but happy with it.
 

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the "PSI" is vacuum....and vacuum changes drastically depending on what position the throttle body is in & how many RPMs the motor is turning. the closer the value is to atmospheric (15psi at sea level), the more you are on the throttle. Doesn't really tell us anything in your context as its listed here. the IAT (intake air temperature) sensor readings are far more useful....now if you could compare those to ambient over a long period of time & weather changes, it would be even better.
 

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Discussion Starter · #4 ·
good to know, I really wasn't sure what the PSI was all about, google only gave me turbo info so I assumed it had something to do with the amount of air.

I will keep an eye on the temperature, I have been watching the K&N for the last half of the summer and up until yesterday and like clockwork it was almost always 20 degrees cooler than engine temp. I'm curious to as what the fresh air setup will run like in the summer.
 

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My experience is that with the cowl intake, the IAT (Intake Air Temps) are roughly 20*F above the ambient air temperature.

During my few days of readings prior to upgrade, the stock intake showed IAT at about 15-20*F below engine temp. Big difference between the two.

There is a big thread over on Jeep Forums about the Windstar cowl intake. I have several posts of my observations a few pages in that match some of what you are describing.
 

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Doing this conversion soon. I also took the chance to cover the inside and underside of the cowl and cowl area with 1/8" thick heat insulating material to keep things cooler in that area.
 

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Seven years and 100k miles later, I can say to anyone that the only reason to do a cowl intake is to make room in the engine bay for other things. Another potential reason is to reduce the engine bay temps which may increase the (very) long term lifespan of the plastic and rubber bits surrounding the engine.There is no performance increase.
 
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