5.7 internals meet outside world

[Spsully]

New valve covers are black instead of that metallic stuff I put on the old ones. Intake painted to match. Trying to figure out where I want to run all the wires.

 

[Spsully]

This is what drives me nuts about wiring harnesses. Tangled up for no reason. Grrrrrr

 

[Spsully]

I think this is my basic plan. Seems to take each wire and hide it behind the closest thing to it. It's all getting wrapped in high temp braided loom and tape that will protect it so much more than the factory plastic junk in cutting off. I'll see what it looks like as i get everything back together and laid out in place.

 

[Spsully]

Dilemma:

So the 06 wiring harness that I have so I can steal the coil pack connectors lays out exactly how I was going to run my harness. I don't know all the differences, but from what I can tell it's just the oil pressure sensor and an extra harness for mds. Even the wire colors to each sensor are the same.

It would be way easier to swap the oil sensor wiring on the 06 than to redo the entire 05 harness like I was starting to do. I'm half tempted to try it and see what I get.

99.99% sure the 06 is can bus instead of pci bus like my 04 and the 05 motor in putting in. But it's so close I almost want to try it.

Cam, egr, alt, Crank, knock, map, intake, water temp, ac comp, ac lp sensor, fuel injectors, tb, o2 sensors, tyranny, xfer case..... all the same color coded wires on all the same pins. I haven't checked the pcm side yet because I'd have to take them apart to do so. But just comparing the wire bundle going into each connector and the connector them selves it all looks the same.

Somebody smarter than me please weigh in on this matter.

 

[HemiLonestar]

06 is CAN bus, but the wires themselves don't know any better. So long as they all go to the same place it should work. Is the connector at the PCM the same?

 

[Spsully]

06 is CAN bus, but the wires themselves don't know any better. So long as they all go to the same place it should work. Is the connector at the PCM the same?

they sure look the same. I haven't taken them apart to match up pins.

 

[Spsully]

Ok final answer to the wiring harness debate.

So i went through both the 2004 and 2006 service manuals comparing all 4 pcm connectors. There are 8 differences on C1. 5 pins aren't there on the 06 and 3 are can bus or mds. Those 5 pins that the 04 has are kinda important like VSS. There are other differences but C1 was the one that sealed the deal.

I'm going with a hybrid of the two. The main advantages to the 06 are the connectors for the coil packs and it is routed much better and cleaner than the 04. I will be running basically an 06 harness to the motor with the 04 harness running to the pcm o2s tranny etc. This means I don't have to mess with the vss and such. I will be using the 04 PS sensor that doesn't exist on the 06 as well as the 04 oil pressure sensor. It was also easier to cut out the mds and can bus wires than it would have been to pull them out and put the 04 stuff where it was different on the pcm side of things

And I am SOOOOOO glad I went and dropped 6 whole dollars on this guy



I think he needs a beard and some tats.

I'm about 40 connections into this project and having that holder guy has been a life saver.

I've also 3d printed different versions of a tool to feed wires into the loom I'll be using. Testing the tool seemed to work unbelievably well. Hopefully in real application is just as fast.

 

[Spsully]

I had the motor ready to go in and the train hasn't stopped in days. So im redoing some of the wiring harness.

 

[Spsully]

Haven't updated in a while.... so here goes

Dropped the factory exhaust and installed my 3" dual exhaust



Wiring harness got finished, but i have to junk the main section because mine is different. So excited about that.

Got my gauges in and wired up. I'm officially a poser. But GPS speedo will be like an hud but actually visible.



Installed my tow mirrors and ran the wires for the puddle lights, so I decided to add some sound deadening while I was in there. This Amazon brand stuff is actually half way decent.

But it wasn't until I took a picture of the test fit that I noticed I have to fix the drivers door

So yeah.... I'll be fixing that too.

I found a smoking deal on a 4th gen console so that had to happen.
I'm not 100% sure howit's going to be when I'm done with it, but it should be so much nicer than the jump seat.

Sat it inplace for a test fit. I think the first step is going to be cutting the jump seat brackets off the seats. They are very in the way. I can't even get a decent idea of fitment because they are so in the way.


Then I have to solve the 4wd shifter issue.
That is what I had before. And this is what the wife jeep is like

And here is what the 4th gen console looks like.

So I got the silly idea to move the cable operated transmission shifter to the middle and bring the tcase shifter up to the same height. It's direct linkage but that won't be an issue so long as I come straight up. Plus I have a bad feeling about all the junk that could accumulate in that center section.

This is what I have come up with so far.


Time will tell.


Also got the old motor out of the truck. Pleasantly surprised how clean everything is. Very minor surface rust. I washed the engine bay with degreaser and streaming hot water. No pictures of that but I need to get some pictures of the rust situation so I can brag to my buddies up north about how little rust is on my 20 year old truck.


Needed a new ac compressor so decided to add a 3500 transmission cooler to the cart. It's twice the size if not a little more.


New motor is ready to go in. Just need to pretty up my engine bay before I drop it in.

Had to break the tires down to replace valve stems. Decided to blast the tired old wheels with some fresh black.


I'm sure I've missed something. But that's a big update.

 

[Spsully]

Took a couple quick pictures of the cleanliness of the engine bay before I started this morning. Still pretty excited about how little rust there is. This would never happen in New England.

 

[Spsully]

Only 2 bolts in the bell housing but it is in its home

 

[Spsully]

Got the motor fully bolted in and mated to the tranny. Installed the ps pump, then decided that the pulleys didn't match so I pulled it off and painted it. Yes I fixed the twisted up ps line.

New ac compressor and alt got painted and installed. (No picture yet) wiper cowl got put back on, everything but the fuel rail and the ac transducer is plugged in.

Before and after motor


I also did a quick touch up on the calipers. Nothing fancy. Heck I didn't even take them off first. When I do the next brake job I'll take it all apart clean it all up and make it pretty.

 

[Spsully]

Been gone for so long you all probably forgot about me. Not sure where to even start.

Motor went in. Ground issues wouldn't let it even try to Crank. Fixed that

More ground issues wouldn't let it start.... seriously? Fixed that

Injectors/ coils wouldn't fire correctly. Acted 180 out. Small ether fire might have happened. Fixed that but I don't know how. I unplugged everything to check and when it went back together it worked.

Truck started but wouldn't idle. Sounded mean af though. Found clogged injector and dead o2. Fixed that.

Truck idles but makes horrific noise. Turns out the dust shield got tweaked during install and the converter bolts were touching.


Seriously I can't make this stuff up. Plate stock didn't have enough to pry the piece back. But I wedged the plate stock between the bolt and that shield piece. Then I turned the Crank by hand. The bolt pushed the plate stock outwards clearancing the shield as it went. Did it three times One with like 16ga and then again with a piece of 1/8" stock. Then I wedged both pieces in there and did it one last time. Now it has good clearance and no noise.

Needed to get the interior back together and wires run for everything. Literally almost died from the heat. Good times. Carpet in, wires ran ziptied, taped etc, and seats back in. Plastics still strewn about the garage.

Now I have to deal with an oopsie I made with my headers. I need to pull my headers off and weld them up. When I port matched them I guess I went a little too far. In low light situations I can see the spark through the headers. But I SHOULD (note the key word) be able to run a bead of weld around the outside of the flange and not effect the flow any.


Other things here and there along the way:
Tailgate damper

Tailgate light bar (opt7 Redline)
torsion keys swapped while putting the suspension back together
HF Icon big wheel creeper installed in garage. Love that thing.

LEDS in the projectors


As she sits right now. I can bolt my front wheels back on and she'll move under her own power. I even have a seat to sit in. Really hoping to have it tuned and driving by the end of the week.

Oh.... and I found out that 1/4 bolts fit in the already threaded holes in the lip of my wheels. Thoughts?



And a picture of the bigger trans cooler because I never posted that



I think you're all caught up. ‍

 

[HemiLonestar]

Oh.... and I found out that 1/4 bolts fit in the already threaded holes in the lip of my wheels. Thoughts?
View attachment 528548

Don't throw your wheel balance off. Or do them all and get them re-balanced.

 

[Spsully]

Beads.... life is always good

 

[Spsully]

And she's mobile.

Still working on the tune and the interior. But I drove her a few times today for data logging.

 

[Spsully]

September 28, 2023

youtu.be

That's today's update