Re: TKat13's Mach1 Build Log
 

Weekend update:
Installed the Canton oil relocator on the block, I was smart this time around and etched a line in the block and the relocator to the original position so the hoses all aligned properly. Made it much easier to install before I dropped it in the car.

Here I go aligning everything and getting ready for the plunge.
https://lh3.googleusercontent.com/-U...o/IMG_3743.jpg

A little closer, at this point I called a buddy to come over and help guide it in so not to damage anything.
https://lh6.googleusercontent.com/-k...o/IMG_3744.jpg

Finally slid it in, the Canton oil pan makes this a little more difficult than the stock pan but it is not that bad.
https://lh6.googleusercontent.com/-u...o/IMG_3746.jpg

Next was to get the poor man's lift (4, 6-ton jack stands) out and have the Mach assume the position, makes the build out much easier by putting the entire car in the air.
https://lh3.googleusercontent.com/-V...o/IMG_3748.jpg

Connected the Transmission, torque convertor, trans-cooler lines, driveshaft and shifter. Motor mounts, Trans mounts, etc.

I figure a couple of hours a night will eventually have this thing back together in a few weeks. I could do a marathon install but I'd either make mistakes or simply not enjoy the work. This way if I get frustrated, then the night ends...

Re: TKat13's Mach1 Build Log
 

Oh man this all looks so familiar...

Re: TKat13's Mach1 Build Log
 

haha, I think we both have had way to much experience with this lately. :)

Made a little more progress last night. Just doing a little here and there and eventually it will be complete. Last night I concentrated on the passenger side; the goal was the passenger header; you have to be in the right frame of mind to mess with the headers but as luck would have it I was relaxed and it bolted right in.
https://lh3.googleusercontent.com/-z...o/IMG_3749.jpg
Header, Starter, AC Compressor and remembering all the wiring - sheesh.

Since that went so well I started on the front of the motor.
https://lh3.googleusercontent.com/-I...o/IMG_3752.jpg
Pulleys, Power Steering (but not the pump) , more wiring, Knock Sensors.

I think I have the 02 sensor in the wrong spot, lol. Actually I am going to replace those with Motorcraft brand, tuner hates the Bosche units.

Tonight after work I plan to install the rest of the oil relocator and the power steering pump. Set my goals low and over achieve, keeps the frustrations away. lol

Re: TKat13's Mach1 Build Log
 

looking really good.

if I lived closer, or didn't have to endure a lot of traffic, I would be in your garage with beer - a lot.

Re: TKat13's Mach1 Build Log
 

You are always welcome, you know where I live. :) Yes, those two bottles of courage helped the motor slide in there.

Re: TKat13's Mach1 Build Log
 

Great progress, I went an got non - Motorcraft O2 sensors (NGK or something), what issues can appear with non - Motorcraft O2's?? Can it be causing my recent issue if 10.1 on WOT? Codes??

The non-motorcraft O2s are much slower, so much so that my tuner turns them off. You can get Motorcraft O2s on Amazon for 35.00 each.

Re: TKat13's Mach1 Build Log
 

I may go ahead and get them since car is up on jackstands..thanks !!
These look right Darrell ?

http://www.amazon.com/Motorcraft-DY1...aft+O2+sensors


These are the ones I just put in 2 weeks ago (got a $20 gift card with them)

http://shop.advanceautoparts.com/p/n...xygen+sensors#

The ECU doesn't use the O2's at WOT. That's why it's called open loop. There's no feedback going to the ECU.

Re: TKat13's Mach1 Build Log
 

Exactly, the O2s will only really benefit daily driving duties. Larry, I would save your money as your problem is somewhere else.

Re: TKat13's Mach1 Build Log
 

Yup, those are the ones. But as yellerCobra pointed out, this is not your issue. Just better for driving around town, possibly minor MPG gains?

Re: TKat13's Mach1 Build Log
 

Couple of updates, first the family was needing some of my time last night so I only got 20 minutes on the Mach, but family time is better than Mach time.

However, I did order some goodies; ordered an intake spacer and new o-rings for my coolant crossover pipe. I also ordered a couple of new V-band clamps from Vibrant, figuring that I will strip at least 1 T-Bolt. After I placed the order I noticed Vibrant sells replacement T-bolts, so I picked one of those up as well.

Installed the rest of the oil relocator and lines. If you look closely you will see a 'scratch' in the relocator. This aligns with a scratch on the motor. This just made sure I installed it exactly in the same spot so no routing line issues. It was a PITA last time I installed this and this time had it done in less than 20 minutes.

https://lh4.googleusercontent.com/-y...o/IMG_3756.jpg

https://lh4.googleusercontent.com/-P...o/IMG_3754.jpg

This is about the same time I realized I needed an oil filter... crap.

Re: TKat13's Mach1 Build Log
 

Lol

Did you have to paint the relocation parts? Looks good.

Re: TKat13's Mach1 Build Log
 

haha, I am anal but not that bad, sheesh. They come black anodized by default from Canton. Although I did order the black -AN fittings to match.... I guess I am that bad. lol

Re: TKat13's Mach1 Build Log
 

Update:
Motor is in, fluids in, shaker is on as well as the hood. The only thing that I have left is the front bumper and headlights, these are always last to go on. :)

Planned on taking it to HPP for a tune this week but as luck would have it I have a gremlin to work out and maybe some ideas from the board on what I am missing.

When I turn the key on, all accessories work, radio, brake lights, interior lights, fuel pumps, etc. However, when I turn the key to start the engine nothing happens, no click nothing. I even hooked up my volt meter and when turning on the key no voltage drop. So, I am assuming no voltage to the starter then.

Here is what I tested:
1. made sure the start switch is connected, aka, in 'park' to start, simply bypassed this switch for testing purposes.

2. Used a jumper cable from negative post of battery to engine block to make sure I did not have a ground issue.

3. Verified all fuses were in working order and validated the proper 12 volts was on both sides of the fuse.

4. Ran the codes on the computer and nothing out of the ordinary popped up.

5. Theft light is not flashing.

6. Power cables connected to starter, but will check again tonight, I was pretty tired when looking last night.

7. Looked for loose connections but have not found any.

8. Battery was on a battery tender, it measured 13.3 volts, by the time the night was over it was at 11.8 volts. I am sure my fuel pumps put a pretty good draw on the battery while I was trouble shooting.

Next on the test list:
1. Measure voltage at the starter before and during an attempted motor crank.

2. Look for any fusible links, does anyone know the location of any fusible links for the starter circuit?

3. kick the sh!t out of it and see if it fixes it

Re: TKat13's Mach1 Build Log
 

Looks like you've tested a few things already. Do you get any other accessories that aren't working when you are in the ignition ON position? Sounds like you'll be basically testing the ignition switch when you check voltage at the starter, which you have listed to try next. I can't think of a PATS situation where the light doesn't flash when it is activated of whatever mode it's called where it won't let you start the car. Have you disconnected the battery to try and reset the PCM since trying to start it? Maybe another reset is in order no that you've tried several things and checked connections.

Re: TKat13's Mach1 Build Log
 

Yep, I thought that as well and disconnected the battery a few times. I would go in the house frustrated, but disconnect the battery not knowing the real issue I do not want to leave it connected. Then after I had some calm thinking time I go back out and try again. I am running out of things to test, I am really hoping I find one of those dumb moments where I forgot to mate a connector. Not hard to do, everything was taken out of the engine bay this time.

My biggest fear is an issue with the PATS system; not sure what to do to completely remove this from possible problems.

Haha yup, I know what your saying. I've hoped to be able to blame things on a brain fart type move before too. Lol

I've seen this PATS thread linked a few times over the years. It's supposed to be good info. I bet you've seen it before too. Maybe there's something in this thread that could give you ideas to determine if it's a PATS thing.

http://www.explorerforum.com/forums/...d.php?t=234975


IG: @azurebluemach

Re: TKat13's Mach1 Build Log
 

Thanks for the help, I finally found it after trouble shooting all the wiring for a couple of hours, I then went and opened the hood to my Daughter's GT and started looking around and all of a sudden I saw it! It was one of the two ground connections right by the battery to the header panel. I had one but the second one had fallen out of view. Unbelievable what a small ground wire will keep from working. lol

Anyway, car is done and will drop off at HPP tomorrow. Started up for the first time and it just idled perfectly, I have am keeping out of boost but man it is hard. :) Drove it around for a couple of miles tonight and forgot how much I love driving it. Can't wait for a good tune and WOT!

Re: TKat13's Mach1 Build Log
 

Awesome! Glad it was something simple to correct. Haha yeah I bet it's hard to go easy. So, any guesses at to what kind of numbers she'll get?

Re: TKat13's Mach1 Build Log
 

My guess is around 700-725 for now, I do have the power robbing Th400 in there as well, I figure my 80# injectors will force me to stop there. I will soon upgrade to much larger injectors and see what it can do but I want to enjoy the car for a while before pushing it. I can already tell it drives much better in 'non-boost' range, simply more responsive.

Re: TKat13's Mach1 Build Log
 

Quick little update - Tuning as usual always brings out the gremlins!

First pull went pretty well, at the lowest setting using the springs in the waste gates it put down 520hp; Boost set to 6PSI.

Went to 8 PSI and started having issues with cutting out; what we found was at the connectors to the COPS, a couple of them got twisted, no bare wire but it seems it was enough to cause problems with the signal. We re-did the pull the stupid radiator hose blew off of the cross-over tube. Moral of story, do not use the factory hose clamps, sheesh. Spent the next hour cleaning up the car/shop emptying out the intercooler, etc. This happened as soon as we let out of the throttle so the turbo did not grab much of the water. Got lucky.

After this we verified that we did not cause any problems and the leak test passed, whew. Had a close moment there. In all of the chaos, I forgot to see what she put down.

After much cleaning and stress induced thinking. We set the boost to 10psi (iirc), this run was going pretty well, power quickly went to 630 and then it cut out again and we immediately stopped the pull. I have no idea if or how much more was left in it. Data indicated it was the Driver side, the previous cutout was the passenger side. Reading the 02 sensors clearly showed when it happened, compared to the passenger output. This showed me why a good O2 is helpful.

Anyway, swapped out 4 of the coils on the driver's side and did a pull, cutout again and even earlier. At this point we called it a day, HPP was staying late to help me out and I did not want to overstay my welcome since the gremlins were making this evening a royal pain.

Today, I stopped by at lunch time and checked the ohms on my original COPS, all were exactly the same, this is good. Manny handed me 4 new spark plugs; during the swap noticed one plug had opened up a bit compared to the others so it looks like I found the problem. Put in new plugs and put my original COPS in the car.

Next week I hope to finish the tune; I have a small exhaust leak that they are going to fix first, then do the tune.

Re: TKat13's Mach1 Build Log
 

Just a comparison from the first time I tune the car; 13psi netted 636HP; 10psi netted 630HP with the new combo. What I failed to ask was how close I was getting on the injectors.

Re: TKat13's Mach1 Build Log
 

Freakin plugs !!!?? After all the work , comes down to a plug...isn't power fun !!
Very happy for ya, great numbers at such a low psi :wings:

Re: TKat13's Mach1 Build Log
 

Following this due to me doing something similar soon! Great work man!