351W and EFI conversion project a success

[Timmy390]

Fired up the 351W last night and let it idle for a bit. No leaks no drips no errors that I could find.

It's been a long project from start to finish but she's done but for buttoning up a few small things. My project started Dec 25th 2014 when I bought the 96 donor van for the 351w. Parted out the van and scrapped what didn't sell. Ended up $65 in the hole. I got the engine block back from the machine shop in April 2015 and started the engine assembly process. In July 2015, the the old tired 302 was pulled from my 74 and the real work began.

Engine, 96 351W punched .020 over. Reused the cam and freshened up the heads. Added GT40 lower (cast iron) and Explorer GT40 upper. New engine mounts.

New clutch and flywheel as well as all new linkage.

Using the Van front dress. Derale 18217 electric fan and American Eagle AE521 radiator. Radiator moved forward (top mounts flipped to outside the core support) to clear the front dress.

G3 alternator upgrade

EFI harness from the van converted from speed density to mass air SN95 harness. Using a mid 90's jeep cherokee fuse/rely box to power the EFI setup and electric fan. SN95 TM04 ECM. Injectors, fuel rail, distributor and remote TFI (black) from the van. 96 Explorer mass air sensor, intake hose and T-body. E2000 pump pulling form stock tank. All new hand bent hard lines with SS braided hose PTFE lined. BC throttle cable and bracket.

Bronco Hut shorty headers and new welded exhaust from headers to Cherry Bombs

Hood scoop added. New Tach along with oil pressure, water temp and voltage gauges.

Factory bench seat ready for pickup at the upholstery shop.

Thanks to everyone that helped along the way.

Tim

 

[Toddpole]

Congrats! I've been watching this swap for a while. Proud for you. Your excitement is evident in your post.

 

[Timmy390]

A few pics

 

[Timmy390]

Just picked up the Bench...

 

[badmuttstang]

Very nice

 

[jmangi62]

Great job bud,now bring it to me so we can make it pretty LOL.

 

[Miker]

Jealous!

 

[Timmy390]

Thanks dudes.....it's been a long road with a few sleepless nights. It should have been done already but deer season got in the way of progress. We get almost 2 months of of hunting in between the youth hunt, special doe hunt, muzzleloader and modern gun. I hunt every weekend during that time. Add in the fact I coach softball (we played 135 games this past summer, and 30 or more this past fall) and time really flies by.

Just installed the ignition switch back in the dash, tucked all the wires up nicely and installed the bench seat.

I still have to shorten the O2 sensor harnesses (I wasn't sure how long to make them) and put the aux tank back on (not using it right now but want it off the shop floor) and I'll be ready for a drive.

I got a small belt squeak at startup. I may have to get a touch smaller belt.

Tim

 

[sanndmann3]

Congrats Timmy! gotta be a good feeling. hope the test drive goes well. I bet you are going to like the new found power!

 

[Illinois73]

Congrats Timmy! I'm jealous. I'm still collecting parts for my 351 build. Thanks for sharing your success.

 

[tasker]

AWESOME job!! can't wait to hear about the road test.....congrats and i bet it was all worth it in the end!!

 

[Timmy390]

Well finished buttoning up everything today. Put the aux tank back on, shortened the O2 sensor harness and set the timing to 10 degrees BTDC (the way the 351W came from the factory).

Tracked down the squeal at start up. I've got to run my belt differently. The belt tensioner is not putting enough tension on the belt. But it looks to be an easy fix. If I put the idler pulley back on and route the belt over it, that should allow the tensioner to do it job much more efficiently. Going to do that tomorrow.

She's purring like a kitten with the timing set correctly. Of course it's raining so no test drive till it clears up.

Tim

 

[mattt]

Nice work Timmy! :thumbs up:

 

[Mark]

looks great! I hope to follow in your footsteps.

 

[Timmy390]

Well as with anything like this kind of project, I do have a few things I'll have to work out.

Ran the system through a full heat cycle. Found a couple leaks which were just clamps that needed a bit of tightening once the system fully pressurized. Took it forever at idle to hit 195 (a good thing), thermostat opened fan kicked on temp went right back down to 190. Looks like all the air is out of the system and she's cooling well. Oil pressure is good at 58 pounds at idle.

How for the issues.....

Belt squeal at start up is clearly belt slippage at the alternator. I need to read up in the high output alts and this issue. Think I've seen a few threads on the topic. It's a 130 amp from the van. My first attempt at fixing it, I ran the belt differently thus had to add a grooved idler pulley but that didn't help. I have the shortest belt possible on it so this will have to be something I track down. I have almost full coverage on the alt pulley but clearly I'll have to figure something out. I already tossed the air pump so I might have to add that back and run the belts as they were on the van. Hope not but I'll figure something out.

Small oil leak at the sending unit "T" that I put on to run the aftermarket oil pressure gauge. Should be an easy fix just a pain to get to.

Sounds like I have a exhaust leak on the D side. Was going to hit all those header bolts after a heat cycle anyway. Could be down at the flange. I'll hit those too.

Got a small tick in the valve train on the D side. It's clearly a tick not a knock. I'll have to pull the valve cover and see if maybe I have a rocker loose. Could be a lifter. I did reuse the old one so if it is a lifter, shame on me.

Man does she sound mean. Backed her out of the shop to test clutch and all. Everything seemed good there. The diaphragm style pressure plate sure is a different feel than the old 3 finger style. Almost effortless....

Letting her cool now so I can check coolant levels. Even with the tick i might give her a spin around the neighborhood after while.

Tim

 

[pcf_mark]

EFI conversions rock you will be so happy with it. On a 10 degree morning when it fires right up and you drive off with no drama it really feels awesome.

 

[Timmy390]

I did take her for a short drive yesterday after addressing the exhaust leak and the oil drip.

Everything went well. The power increase from the old tired 302 to the rebuilt 351W is crazy.

Now to look for the at startup belt squealing issue.

Tim

 

[Timmy390]

So after some research on the belt squeal issue, I'm already running one of if no the biggest alt pulleys available. It's 2.75 inches. Clearly the positioning of the belt tensioner is the issue. It's just not able to do it's job well enough with the current belt configuration.

I decided to add a "smog pump" eliminator bracket. Proform Part 68110. It's for a 5.0 but reading the reviews they also fit 92-96 F-150's with 5.8L so it should fix the van bracket as well. I'm already running an A/C delete bracket so what's one more.

I'll be able to use the stock belt and routing once the bracket gets here. Fingers crossed for Friday delivery or sooner....

Tim

 

[Timmy390]

The "smog pump" eliminator bracket Proform Part 68110 is here, installed along with a stock 96 E350 belt and the squeal is gone.

Now on to the oil drip at the pressure sending "T" in installed. Think I'm just going to eliminate the old sender and use the aftermarket gauge I installed. What is the need for 2 anyway. That means I can gt rid of the "T" that's being a pain.

Tim

 

[EFI Guy]

Nice job Tim! Glad to hear the fans work too. You looking for a second job?=)