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Hi:
I'm busy cataloging modifications I need to make to my upper and lower splitport intake manifolds. I will document this more thoroughly later but right now, I could use some advice from other folks who have adapted the splitport intake+heads to a tbird.

Upper Intake Manifold
- Need to install the Intake Air Temp Sensor to the intake manifold
Q: Where do you guys drill and tap the intake manifold for the IAT sensor?

Lower Intake Manifold
- I see three items to install here: ECT Coolant Temp Sensor (for PCM), Coolant Temp Sensor for gauge, and Air Bleeder Bolt (must be at highest point of coolant system).
On my 2001 lower intake manifold (same for all 99-04 lower intake manifolds), there's only one pre-tapped sensor mount point at an angle next to the thermostat mount point. On this front, I think I have this pretty well figured out based on a pic I saw of bay_bird93's lower intake manifold. I can simply drill and tap just above the thermostat mount point at a point that seems well marked from the factory.

I'll post more of this stuff later once I've made it through this swap. Thanks in advance for your advice.
-g
 

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On the Singleport 3.8's, the two coolant temp sensors are in the crossover section of the intake manifold - both are on risers / water outlets, the one for the heater core, and the one near the Thermostat. Anywhere in this area or T'd off would be OK.

Air intake temp .. usually this is installed in the Air Intake box, or the Intake tube .. not necessarily the manifold - the manifold can get hotter and give different readings than the temp of the air coming in through the intake tube, mis-readings could throw off the air/fuel ratio. Any sensor on the intake is usually for an intake pressure / load sensor like a Barometric pressure sensor. Only the SC's used the Baro for altitude adjustments and they are seperate from the intake manifold. The 1993 3.8 NA PCM you are using doesnt use a Baro sensor, it calculates air volume with the MAF, IAT and TPS sensors.
 

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IAT- Mounted in the air box



Coolant Temp Sensor- Lower intake manifold



Misc. Coolant Sensor (For my electric fan)- Coolant tube



ECT- Lower intake manifold

 

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I drilled and tapped the split port intake on that boss right by the thermostat. I never even removed the intake from the engine to do it. I did it right on the engine stand. Use lots of rags to stuff the holes so the shavings cant get away from you, then do a meticulous clean up job! Its easier with the intake off because you can flush the shavings away with water after drilling and tapping.

I agree with sctbird, nothing wrong with a tee to put 2 sensors in one place. It worked great on my 94 for years until I went with the CHT sensor instead of ECT for a cleaner look. I would like the IAT sensor in the airbox as well. With the right grommet or some JB weld, that shouldnt be a problem. I have only seen IAT or ambient temp sensors go bad when people hit things and bend the car up, breaking the sensor.
 

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To bump an old thread...

I'm currently doing a similar build. I need to have the 2 factory gauges, and I'm also adding an aftermarket gauge for accuracy and redundancy. The heads that I have came from a 1999 4.2 and they have the rear head temp sensor. Is this of any use to me, and if so how do I tie it in? I plan to have the bosses on the front of the intake tapped, but I'm looking for a place for the aftermarket one. Could I use the head temp in place of one of the stock sensors, and then use the front intake location for the new gauge?

Edit: I believe I can use the head sensor for the computer. They are both 2 wire, so I'll just reroute and repin for the different connector. And then run my new sensor in the front of the intake.
 
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