Twennyseeks

How did you guys go about mating an S4 intake on your GSL-SE, Ive got one on the way and am wondering what I will have to do. I know Pjay had a good writeup but all the images were lost. For reference the port im talking about is the lower middle one. (Images stolen from other threads)


Is it the ACV? Would the ACV Cover plate from Racing Beat work for this job?

Richard Miller

I packed some aluminum foil into the port and sealed with high temp epoxy to block the center iron.

peejay

Steel putty on the intake manifold. Very easy to do.

Here's a photo montage of modding an SA intake manifold to fit an FB engine.

SA vs FB manifold. FB has air injection port in the intake manifold. SAs injected air through the exhaust manifold (thermal reactor) flange.


After a lot of cleaning, two screws get installed for mechanical grip.


Then Quiksteel or equivalent gets globbed on.


Checking with FB intake gasket to make sure there is enough globbed on.


After being allowed to set for a day, it gets filed flat, and the gasket outline marked to clearance the perimeter. Excess material here can sometimes interfere with the exhaust manifold, so after one time I had issues, I always clearance the perimeter.


And done!


One thing to note when cross pollinating S3 and S4 13B lower intakes is that the ports are different sizes and different heights. I think the S4 intake ports sit higher. What I have done in the past is add some epoxy to the port roof in the intake manifold so the air doesn't run into a step. What I found was, when disassembling that setup because of a different problem, the epoxy had broken out and was loose in the port.

Twennyseeks

Ayyy thanks for the visual help. If you could have done the port differently what would you have done? Having loose globs of putty in the intake makes me a bit nervous

Twennyseeks

Little update on this project! I got the intake off of ebay (including the throttle body! wahoo!). I had some shop time at the school yesterday so I began the herculian task off taking it all apart so i can get everything nice and clean and up to snuff. This include spraying just about everything with PB blast so if that ruins any parts, let me know.

Like I said, its a junkyard part (I assume) and it SHOWS. I get the feeling some parts (5/6 actuators/diaphrams look really rusty from the outside, unsure if theyre gonna work, port rods were really hard to pull out) are probably shot. So I ask, how much of the parts are interchangeable from an S3 GSL-SE intake? Can I re use my actuators from my working intake on this S4 Intake?

Thats probably all I can think of now. The intermediate did have a slight dent on one of the runners, but I doubt it will have a major impact.

I finished the day off with sand blasting tge intermediate, and putting the fully disassembled upper, lower, and intermediate in a parts washer.

Next chance I get ill be cleaning the rest up. Unsure what to do with the throttle body though, I just took it off and set it to the side. I also may not sand blast the upper, as I dont want to damage the plastic plate that sits between the upper and the throttle body.

Edit: Forgot to also mention I might be getting some Atkins 5/6 port inserts!