1G Intake manifold questions - tapping, cleaning, heat spacer

[ErikTande]

I'm going to pull my intake manifold and tap it for a boost source for my GM Style 4-bar map sensor.

What size tap and bung do I need? Is 1/8 NPT threads to 1/4 barb?

What's the best way to clean the inside of the intake manifold when it's off? Oven cleaner and pressure washer?

Is a thick spacer gasket worth it? My EGR is blocked, does this gasket still work?
https://www.amazon.com/MAPerformance-Manifold-Thermal-Mitsubishi-Plymouth/dp/B00QMSAS7E

Thanks!

 

[92AWDHX40]

I was going to get a theremal spacer but decided not to now, I used brake clean and power washed out the intake at the car wash.

 

[1990TSIAWDTALON]

Erik, when I was rebuilding my Saturn, all aluminum block/head motor last month, I found oven cleaner to work quite well in cleaning up some varnished areas of the aluminum, inside the block, where oil would have gotten warm and varnished. It was just a thought I had, as when I was married, it was my job to clean the oven. Works great on aluminum but make sure you do wash it all off or out. It should clean it up really nice, it did the inside of the Saturn motor, which, by the way has 500 miles on it as of this morning and its oil is still see through so cleaning the inside was well worth it. I expect it would take off any gas residue and such in the same way, just hose it down good so none is left on it. I would do it OUTSIDE too, as the fumes got a bit strong .
Marty

 

[ErikTande]

Ha, I've been working on my 97 Saturn wagon recently, I love those cars, dirt cheap and a breeze to work on. I just replaced the front brake rotors, pads, inner tie rod ends, outer tie rod ends, control arms and front shock assemblies for $250. GM Parts bin for the win. Just keep oil in it and they keep truckin' forever.

 

[1990TSIAWDTALON]

Off topic, but have you had one apart? I was AMAZED. It had full floating pistons with skirt coating, forged crank and the baddest looking main girdle. And all stock. Hell, I spent good money on a Kiggly main girdle for my DSM and this little 1.9 had it already on it. Super impressed with it, crossing fingers.....it is a 2002 SC2.

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[1990TSIAWDTALON]

And hey, the 1/8 thread 1/4 barb should be perfect for the GM Map. Its nipple is about the same size, mine is mounted on the firewall with a Camaro Map mounting bracket from my sons car that we don't use that stuff on.

 

[ErikTande]

Nice! Did you drill extra drain holes in the pistons to fix the oil burning? Lots of threads on that here: http://www.saturnfans.com/forums/forumdisplay.php?f=23

 

[Mello]

HEADS UP on the oven cleaner, it is caustic on aluminum like Purple Power. The cans I've used had warning in small print on the sides of the cans. I didn't let it sit long or dry out & as long as you get it rinsed well it won't causing discoloration of etching. Billet is easier to get rinse than cast aluminum too.

 

[1990TSIAWDTALON]

Yep that is true. It works fast so spray on let sit for 5 mins and rinse the heck out of it. I worked in small areas at a time and it cleaned all the varnish very well.
I wouldn't spray it on and go away. I even used an old tooth brush to get to small areas. The tooth brush wasnt much after the scrubbing though.

 

[1990TSIAWDTALON]

Nice! Did you drill extra drain holes in the pistons to fix the oil burning? Lots of threads on that here: http://www.saturnfans.com/forums/forumdisplay.php?f=23

I will read up on "drain holes"....but she hasn't smoked or leaked or dripped at all. Even on 1st startup, no smoke. It's like a sewing machine, very quiet and smooth.
Thanks for the link Erik!