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Discussion Starter #1
I have finally started and almost finished my engine swap. Something to consider if anyone is interested in an 04 Explorer motor w/an early non pi AED kit. The deck height of an 04 Explorer motor is approximately 3/4" shallower than the stock 97 block. This posed quite a problem when putting on my AED kit. Turns out there is a vacuum operated blowoff valve on the underside of the supercharger. The tube that runs from the butterfly to the underside of the upper plenum needs all of that 3/4" to fit. Well after about 3 hours of messing around and fabrication we were able to get the tube modified so that it would fit. Of course it took some milling of the butterfly valve and the tube and we also had to cut a section out of the actual tube but it all fits and will work wonderfully I'm sure. Anyway, I guess with this kind of thing there are bound to be issues that surface.

Not sure about the deck height of other 4.6's but if your putting on an AED kit it matters.
 

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My guess...

thunder chicken,

I would assume the aluminum 4.6L has more material since it's not nearly as strong as cast iron. As for the deck height, they should be the same. I think you mean the space in the cylinder head valley is shallower.

954.6tbird,

REV-I ALLEN kits were originally only NPI but Mike Siska and I changed that. Soon ALLEN SUPERCHARGERS offered NPI and PI REV-I kits. They re-designed the REV-I runners and added more material in late 1998 to accomodate COP ignition (coil on plug) for the 1999 Mustang GT. The trucks also had the COP ignition and they were in the truck market as well.

By adding more material to the runners you can port them to match PI style ports.

In other words, ALLEN sells both PI and NON-PI REV-I kits.

If you want to change your NPI runners to PI style you have to port them. A spacer is a waste of time and money.



NPI REV-I RUNNERS ON TOP
PI REV-I RUNNERS ON THE BOTTOM

A-Train
 

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954.6tbird,

REV-I ALLEN kits were originally only NPI but Mike Siska and I changed that. Soon ALLEN SUPERCHARGERS offered NPI and PI REV-I kits. They re-designed the REV-I runners and added more material in late 1998 to accomodate COP ignition (coil on plug) for the 1999 Mustang GT. The trucks also had the COP ignition and they were in the truck market as well.

By adding more material to the runners you can port them to match PI style ports.

In other words, ALLEN sells both PI and NON-PI REV-I kits.

If you want to change your NPI runners to PI style you have to port them. A spacer is a waste of time and money.
ah ok:eek: dont mind me:D
 

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Discussion Starter #5
actually I didnt use any thing between the heads and the runners. Yeah they are different but not enough that the gasket wouldnt accomodate. Just bolted them right on and torqued them to correct specs. Hopefully it will stay together ok.

As far as the shallowness and where it came from, I'm not sure but I do know that it was 3/4 difference and a pain in the you know what.
 
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