Northstar rebuild: Will style (Page 115/119)
IXSLR8 AUG 05, 03:25 AM
Going to be a clean engine look when you are done!
Will AUG 13, 11:02 PM

quote
Originally posted by IXSLR8:

Going to be a clean engine look when you are done!



Dam Str8! I just built it...

*************************************

Made great progress today.

I found that I completely failed to get 20ga ORN wire, but needed 4 circuits of it across the manifold production break and both coil pack connectors. 32 feet ordered tonight, along with 10 more feet each of 16ga BLK and 20ga PPL.

For the 16ga BLK and 20ga PPL, I am the victim of my own estimations. I needed 112 inches of 20ga PPL and only have 97 inches left. The chunk of 16ga BLK was smaller, but still only needed 112 inches. Ooops. That's my third order.

Manifold production break is populated, except for two 20ga ORN wires. The Bank 1 coil pack connector is fully populated except for 20ga ORN, while the Bank 2 connector is lacking 20ga ORN, 20ga PPL & 16ga BLK.

After completing the manifold break and the coil pack connectors, I'll only have the CTS, DBW & MAF connectors to build before I need to pull the engine off the stand and bolt up the transmission in order to build the VSS and back-up light connectors.

My manifolds are with a Cerakoter and I'll need them back to build the wiring for the O2 sensors.

I have a big bundle of wires that will go through the firewall and become a giant PITA to terminate at the ECM inside the car.
Will SEP 04, 06:59 PM
The throttle hose nipple diameter is 3.514". The MAF hose nipple diameter is 3.680ish. Who makes a 3 11/16" to 3 1/2" silicone reducing coupler? Lol. I snagged a 3 3/4 to 3 1/2 that looks workable when I squeeze it down on the MAF with a hose clamp, but the MAF slips out otherwise.



I had to cut this weird notch in the coupler to go on the MAF all the way



I finished the manifold production break with the 20ga ORN wires, and added the 20ga ORN to both coil pack connectors, as well as the 16ga PNK to the Bank 2 coil pack connector. The 16ga BLK is on backorder, so whenever it shows up I can finish the Bank 2 coil pack connector.
I got as far as the 3 wire CTS, which has the second wire so far going to the C500. There's not much left going to the C500 with this system.

Remaining on the engine:
Bank 2 coil pack harness 16ga BLK (1)
DBW Throttle (6)
MAF (5)
EV6 injector connectors (16)

Will need to snag manifolds back from the cerakoter before I can wire up the HO2 sensors. And of course bolt up the transmission before I can wire up the VSS and backup lights. The C6 ECM also has provision for a transmission fluid temperature sensor... Now I have to figure out how and where to install one in a 282.

Getting to be lots of wires here:
Will SEP 04, 07:01 PM
I did not devote the entire weekend to The Mule, as I have some PDH's for my PE license that I have to complete, but I did get some things done.
The 22ga TAN wire arrived, so I was able to finish wiring up the MAF. The TE wire seals arrived, so I was able to wire up the DBW throttle.
The 16ga BLK wire is still on backorder, so I have not been able to finish wiring up the Bank 2 coil connector.

MAF mounted with fancy Gates hose clamps and wired up

This images is larger than 153600 bytes. Click to view.

Developing harness around the visible rear corner of the engine



Bank 1 coil connector shrink tubed and approximately in position for a p-clamp to a convenient hole in the valve cover



Getting started dressing all the branches on the front of the engine



Quickie of how far down I was able to use 3/8" DR-25



Flash photo of the dressed harness for that area; Maybe I can join the AC pressure transducer (3/16" tubing) and the Compressor Clutch connector (3/16" tubing) in one branch of 1/4" tubing instead of two branches of 3/16" tubing. PITA at this point to do that, though.



With the alternator bracket in place to hold it down.



The one thing I'm concerned about is the sharp edge of the Cometic head gasket sticking out of the block/head interface. I will probably add some kind of edge protector to it.



Next weekend: Coil pack harnesses

Edit: Proof that Mouser will drop one dollar of wire seals in a box and ship it to you
Will DEC 23, 09:18 PM
I had a friend over to help and we moved the engine over to the QC lab for some follow up glamo(u)r photos and a "final" weight.







373 lbs including
  • flywheel & clutch
  • waterpump
  • Accessory brackets
  • Throttle & MAF
  • Coil pack & plug wires


NOT included
  • Exhaust manifolds
  • Alternator
  • AC compressor
  • Wiring harness


I won't be moving the engine again, but I'll get additional weights as I install more pieces and assemble the drivetrain. I'll get a "fighting weight" of the engine with the exhaust manifolds, accessories and all the mount brackets. I'll get one with the transmission and its brackets and intermediate shaft. Then I'll get a final one of the fully assembled cradle (probably with control arms because they're already installed).

Today I spent too much time futzing with the harness dressing on the front side of the engine, screwed something up and redid it twice... But now I'm satisfied with the result







And installed the cerakoted exhaust manifolds so that I can wire up the O2 sensors.



[This message has been edited by Will (edited 12-23-2023).]

Will JAN 17, 04:35 PM
I decided I had gotten everything done that I reasonably could on the stand and it was time to pull the engine off the stand and start assembling the driveline.

Here's the "fully dressed" weight:



Included:
Everything from last time PLUS:
  • Exhaust manifolds
  • Alternator
  • AC Compressor
  • Tensioner
  • Wiring harness
  • Both engine mount brackets


I ran into a couple of snags installing the transmission, but nothing severe. Shaun isn't the only one who has interference problems with the shift linkage





And the weight with transmission



Included:
Everything from the fully dressed weight PLUS
  • Transmission
  • Transmission mount brackets (all four drivetrain mount brackets)


Does NOT include:
  • Intermediate Axle
  • Intermediate axle bracket


Here's the follow-up measurement of the clutch throw out linkage. The quoted measurement is the same clutch with the stock TOB. The new measurement is with my TOB holder and PTTs conical faced TOB. Now I guess I need to take the same measurement on the Storm Trooper to see how my stack compares to a stock clutch with a few thousand miles on it.




quote
Originally posted by Will:
This is with the stock TOB holder installed inside the bellhousing. This dimension should come down about 0.350" once I get my new TOB holder finished.







Edit to add:

Not sure how the measurement changed by 9/16" from switching between these two parts. Did I screw up on the first measurement? Maybe I screwed up on the second measurement... at least I can revisit that one.


quote
Originally posted by Will:
Stock vs dual disk unit



Easiest Install-for-Flight ever!



[This message has been edited by Will (edited 01-28-2024).]

La fiera JAN 20, 11:03 PM
Good to see the progress Will!
Will FEB 13, 05:20 AM
Before I left for Tokyo, I finally got the coil pack harnesses DONE. The coil pack connectors for each bank have seven cavities. Four are for coil signals (positive side). One is for signal ground for all four signals and goes back to the ECM. One is for power for all four coils and comes from the coil/injector power fuses which are fed from the PWRTRN relay. One is for the power ground for all four coils and just goes to the vehicle ground scheme.

Because there are three contacts in each connector which each have to connect to all four coils, there are a bunch of splices in each coil pack harness. I used closed barrel crimp butt splices with Raychem RNF-100 shrink tube (rated for 125C temps, so can be used in the engine bay). Because of the length of two splices in series with some wire in between, packaging it all on top of the rear valve cover was awkward. If I ever need to modify these, I'll use multi-wire open-barrel crimp splices like GM used. Those would be MUCH easier to package than the way I did it.

















I have not been back to work on it yet, but should this coming weekend.
With the transmission in place, I can wire up the VSS and back up lights. I should have the new MAP wires as well.
My goal this weekend is to get the powertrain on the cradle. That should be just a matter of dumb assembly. I also have to come up with a plan to modify the Sprinter manifold going into the Jeep to clear the original Jeep fuel lines. That will take some of my time this weekend.

I want to check to see if the TOB holder is still in place. If I can't do this using an inspection mirror, then I'll have to R&R the transmission. Obvi that happens before the powertrain goes on the cradle.
La fiera FEB 13, 10:50 PM
Will, so you are sequential now?
Will FEB 14, 09:49 AM

quote
Originally posted by La fiera:

Will, so you are sequential now?



Transmission or fuel injection?