"Added by eddie, posted by 410custom"

here we can see the holley wiring has made its way into the cab! (Cab floor needs a cleaning Yes I see that too!)



now to sort out some of the hurdles. I had to figure out a fuel line and power steering high pressure hose solution. The 07 Ranger is different from the earlier trucks, the stock fuel line runs up the spine of the v6 transmission. The high pressure PS hose also mounts to the track differently.
I found a 02-05 4.0 power steering line is able to be made to work.






PS line will need some bending to be perfect, but it works






has a funky bend in it, could have a custom line made if needed by modding this one, but lets see if we can make this one work even with its funky routing. I have a large line bender that really helped to shape it






PS line sorted!!

The fuel line I snagged from a 02 sport trac, plugs into the 5.0 and plugs into the 07 style fuel filter.

Time for some routing and under hood mods, lets get this 5.0 put together!



the stock 5.0 starter/ ground/charging harness has this metal bracket that ties into the explorer frame. It keeps the wire loom away from the oil filter and fan, so we will re use it. To make it fit the ranger frame better I cut it up a little bit, drilled a pilot hole and mounted it with a self tapping screw. here you can see I am using a C clamp so I can bend the tangs and free its grip from the wire loom

Install the top "tab" the ranger frame has a spot for it, then mark the hole on the bottom where to drill (oval mark)






arm cut off, hole drilled


While we have the grinder out might as well take care of two more brackets



When running a 1" intake spacer the coil tower and throttle cable holder need some mods. Basically cut off some bits



parts removed, let the mods begin!


All parts sent off to the parts washing department (me)

Wiring bracket final install





Everything is cleaned and prepped before install, need to find a home for the coil drivers





Meanwhile, remember this little gem? I dug the cv axle out so I can ship it to RCV for repair...... fingers crossed 


 

Next items to be wired to the Holley harness, IAC, TPS, CTS, and coil packs. Factory 5.0 pigtails soldered to Holley wires, wires cut to fit my under hood routing.




Holley oil pressure sender installed to the 5.0, just then I realized I will need two oil pressure sensors, one for the stock dash also. So I ordered a dual mount for a 302 from Ebay, $30


Once it arrives I can install both sensors



Messing around with fuel lines, somehow I ended up with two 06-11 Ranger lines? I also tried a 05 ranger line, it would have needed an adapter, then finally I found the 02 sport trac line will be plug and play. Had to swap the heat shield also on the ranger frame...they are different in 06+ more on that later

You can see the Holley coil pack (ignition) wiring has been routed down the drivers valve cover, wrapped and loomed.
Heater manifold and hoses installed. The fuel injector harness was final wrapped and installed. Cam and crank sensor wires routed...this engine bay is ready to go together!!

test fitting the upper plenum, getting some measurements for possible COP/ LS coil install



2.5" clear under plenum on drivers side, this is with the 1" intake spacer



tons of space on the passenger side


3.5" vertical clear at top of valve cover
5.5" at the bottom





Now I need a EGR block off plate for the back of the intake plenum/elbow. Time to fabricate!



Gasket is traced onto 1/4" plate





band saw and grinder, then a hand file and BLAMO
EGR block off, oh yeah I cut a new gasket too






 

Speaking of plugging up the EGR
the new Drain plug / TMH EGR bung plug arrived today
stainless 22mm 1.25 pitch drain plug with gasket
Will get some anti seize and final install. I ordered two, I am sure I will need another one of these!







Before the intake goes on the engine ground strap is added



Now soldered

final paint



I changed up the vacuum line a little bit for the back of the intake. Now it has two feeds, one for the fuel rail damper and the second will be for the Holley PCM built in MAP 

more on wiring the waste spark ignition and mounting of the coil drivers. I am very happy with how this turned out!




bracket back from final paint shop (me), here you can see how the holley ignition harness is routed along drivers side injectors and to the back of the coil tower




the TMH, EGR block off plug is installed fully, anti seize on the threads. This is a 22mm 1.5 pitch drain plug (not 1.25 like I said earlier)

Now before I cut the Holley plugs off the coil drivers on the coil pack side of things I needed to carefully mark the wires with their corresponding pin letters, as you can see all of the wires are black, so this is very important to get it right. I triple checked before I cut a wire. The connectors are labeled very faintly with letters. I used a black marker and wiped it off on the white plugs, so I could see the letters clearly. On the black plugs I could not do so, so I used tape





On the output side of things (coil pack side) wires A-D are the coil driver wires (signal) and wires E-H are the red power to coil wires, all 4 wires E-H are the same, basically switched power to coil. I only need one red wire on each coil pack, for good measure I used two and capped the other two off





Coil drivers marked, one feeds cyl 1-4 and the other 5-8< DO NOT MIX THEM UP!!!!! Very important that cyl #1 wire leaves PCM, goes through coil driver, and ends up at Cyl 1 coil..... same is true for cyl 2-7. This wiring was done very carefully, checked several times along the way before final wrap!!



At the end of the day (or ignition coil harness) we only have 6 wires
Why? Because the Ford waste spark only uses 4 coils.

The chart I made earlier shows this very clearly, ALSO the PDF file WILL BE updated, earlier I had the wires labeled wrong!!
I am working on updating it today (06/20)




here you can see two coil signal wires come together to feed a single coil.
Wiring is done per the PDF chart I posted earlier, MUST BE DONE PERFECTLY!!!!!! or you can destroy your engine (not likely) but Holley makes it very clear you must have a professional (like me) install this system. A full understanding of why this is wired the way it is is needed, do not just copycat something you see on the net, you need to know the ifs, whys and buts of this wiring. Your harness may use different pin locations or wire colors! Mine is a Holley kit made for the Ford 302 and 4r70w, the injector harness and main harness match up. Then I custom wired the GM coil on plug ignition harness to be a Ford waste spark ignition. CAREFUL folks.

Last edited on Tue Jul 26th, 2022 01:33 pm by Eddie Money

"Added by eddie, posted by 410custom"

I have updated the CAD/PDF file with the correct coil driver output pin numbers/wire colors. I simply had the cyl wires backwards on the last version. This is now the AS BUILT document





PM ME for the PDF or CAD file of this chart

Last edited on Tue Jul 26th, 2022 09:14 pm by Eddie Money

Attachment: TERMX TO FORD DIS 073022.pdf (Downloaded 2 times)

JAMMAN wrote:
OK just tried one that was 10.4M, something is broken. I'll have to look at it myself I think I scared Chris off...

OK I got it to work, but download took forever. Who configured this server anyway? Wait....
It Works. Thank you

If you are looking for a readable version

download the PDF in JAMMANs post

Last edited on Tue Aug 2nd, 2022 11:47 pm by Eddie Money

okay with the coil pack tower all completed I could finally move on to finishing the rest of the under hood wiring/ plumbing



This is oil pressure port for 302 engine allows you to install two oil pressure sensors. I ordered two of these so when I build my sport trac I can have one too!







Installed into the engine with thread sealant. The factory dash oil pressure gauge for a 98 5.0 was used as well as a Holley compatible pressure transducer for the Holley PCM to monitor oil pressure








paint had begun on the upper intake. Intake was stripped of all the plumbing and accessories, thoroughly washed and cleaned. then primer and paint...... this two tone paint job took me a bit to accomplish, I love the end result. I wanted to keep the final appearance a secret but that would make life really difficult for me trying to hide the upper plenum from all the pics.
So here it is! The final paint scheme, I wanted to match the holley coil drivers and also keep the red/black/grey theme going (calipers, rear axle, etc)











The intake plate was color matched to the grey then I hand painted two coats of black inlay.
The intake plate may change later................ something custom could easily be made.
I also hand painted the tops of all the fasteners after the intake was assembled




after first coat of black, before touch up. I like getting to use my artistic skills once in a while.......not many things hand painted anymore




sneak peek of it resting in the engine bay


match the Holley color scheme and our truck win win 

Last edited on Fri Aug 5th, 2022 09:23 pm by Eddie Money

Last edited on Fri Aug 5th, 2022 09:25 pm by Eddie Money

here are some close up shots I took for Eddie to make him drool, he said I can paint good (I am a classically trained artist and I went to graphic design school)

I even painted the bolt heads after I installed the elbow

had to tidy up the engine bay, lock all wires into their final positions, route all Holley wires properly around the heater hoses and down the spine of the trans.

final wrap on all wiring










Lower intake was cleaned, upper intake, gaskets and spacer was prepared for install
the upper intake gets some plumbing underneath before hoisting it into position






cleaned all parts and added the custom vacuum line that feeds the fuel pressure regulator and the new Holley built in MAP sensor, the PCV hoses and brake booster hoses.
Intake mounting surface cleaned, spacer cleaned, gaskets and bolts set in place and finally install



I have some tricks I use, like for example you must have the rear long bolt in place when you put the intake up there.... I use a plastic clip to hold the bolt up so it does not interfere with teh placement of the gasket, spacer, gasket, and intake sandwich





DONE!!!!!



coil tower installed, some detailed shots

with no EGR plumbing it sure is nice to have all the room in the engine bay, makes a nice spot for the Holley PCM to injector plug and Holley PCM to ignition plug






coil tower in! Throttle cable, shifter cable going in
Now to mount the alternator, AC compressor, Power steering reservoir, belt, fan etc etc finish up the engine bay, put this sucker on some wheels so I can access the cab and get to the dash/cluster/steering column/ and seat install

some factory dtrs wiring info for our friends






Above this is 05 Ranger book

Below is 2000 Model (98-01 5.0)





And finally the 97 5.0 DTRS (96-97.5)

Back on wheels and tires!!
Sorry she is so dusty, once the engine bay is finalized I can back her out and give her a proper wash











All wiring is in plumbing is happening
time to finish up the engine side of things
this means LOTS of cleaning parts and looking for the right bolt!! LOL


First up power steering reservoir, was cleaned inside and out

the remaining wires in the C110 plug will be removed once she is running and we decide they are all not needed

coil pack resistor was installed

Oil filler neck is in




Modified throttle cable bracket installed



next round of parts for cleaning



almost ready for a belt



throttle cable in, some vacuum going in, time for the ac compressor and line



everything is dismantled and cleaned.
The washer/overflow tank is easily cleaned with de greaser, if you need to clean the inside fill it with pea gravel and soapy water, start shakin!!



ac compressor, line and shield up next
Nothing better then 104K mile OEM parts!!



cruise control / speed control servo is in
alternator cleaned and going on



ac line is in, needs some heat wrap to hide the ugly



cruise cable, ac line, alternator and alt wiring in

vacuum line modded, I need the feed for the HVAC system (Heat and ac) but we no longer have the EVAP system (fuel tank vapor management) so the vacuum for that side is deleted.



small fine thread bolt with some silicon patches the hole



move some power steering hoses and some lines in prep for the ac compressor



cleaned and final drain of old ac oil



Yeah buddy finally a BELT!!









IAC is dry and installed

Its all the small things


Ready for intake air tube, ac line wrapped with some heat shield




I used the throttle bracket and cover to hide these pigtails, one is for Holley fuel pressure sensor, I have not installed
Second is for a GM style 3 bar MAP sensor if needed, the Holley has a MAP sensor built in we will be using, but if you ever add boost they recommend using an external MAP, so I left the pigtail. 

throttle cover on, overall engine bay! Dang shop cats leaving prints all over the truck..... Its ok soon she goes outside for a spray off

Last edited on Wed Aug 10th, 2022 12:03 am by Eddie Money

Last edited on Tue Aug 23rd, 2022 03:34 am by Eddie Money

new radiator has been sitting in a box for a while, finally time to install!
First the 07 AC condenser was cleaned inside and out then installed, now I could lay the radiator down onto its mounts.
Dual factory trans coolers were also cleaned inside and out ready to go in






sexy!!














now for the fun part

she's outside and wet again ooooooh la la


SOOOO GLAD to get rid of all the dust

"Ace" approves everything that happens in the shop

I love the stance of this ranger!!

The pictures do not do it justice, she is super sharp in person




the goal was the overhead storage where the dash and other goodies have been hiding all of this time






After the AC condenser and the radiator were installed, the dash and interior wiring have started to go into the truck!!

Last edited on Tue Aug 23rd, 2022 03:50 am by Eddie Money

MUCH OBLIGED to Mhoward for already doing this mod and giving me his blessing to add it to my truck, and 410custom for agreeing to do it for me. Thank you both!!

Here is the link to Mhowards "how To thread"
https://ford-rangers.com/forum58/1802-1.html

"Added by eddie, posted by 410custom"

Now more goodies
We will be doing a console shifter in this rig no column shift!!
So to start we are using this setup from another ford


Packing peanuts!!!! Party foul. I hate these things



Hiding in there was 2010 mariner console, wicked cool.
To go with it eddie sent me a  08 escape shifter and trim piece as well as new paint for the whole she bang bang
I get to hack this up and make it fit between our seats, as well as hide the Holley pcm

Muahhahahahaha


 


Nasty, going to need some serious cleaning and prep. It did come with all the parts and pads which is awesome!!

Our buddy @mhoward has already done this conversion before us so that is where the idea came from really updates the interior. Will go well with our 2014'seats!!
I'm not sold on the escape shifter though it looks cool it is also 18”'tall! I may gut it and install an older stang shifter to make life easier but still look like the escape unit

Last edited on Fri Sep 16th, 2022 10:34 am by Eddie Money

the second coolers flange is bent straight for better mounting to the ranger







return line is cut to length, filed, and a simple flare added









done

Last edited on Mon Sep 26th, 2022 01:57 pm by Eddie Money

I added a 30 amp fuse for out alternator IVR feed AND I added 3 more..........wooooooohahhahaha
Now I have 3 fused feeds of battery + I can utilize simply by adding the fuse

The alternator IVR power wire does not just run directly to the SJB, in order to make it like factory and easier to remove the engine this wire is run through connector C139....more on that in a minute







red wire near brake booster is coming from new fuse, to truck side of C139 (female)
I created a new male C139 so our wiring will plug into the truck just like stock

The 5.0 harness uses a similar 12 pin plug, but it is also female....
Other wires that run through here are oil pressure switch to instrument cluster
dark green/white, careful here the dark green with white on the 5.0 side actually goes to the oil level / temp switch on the side of the pan. I ran a new wire directly from this plug to the stock oil pressure switch

AC high pressure switch is Red/Yellow and black/white, all of these wires pass through the the new male C139

white with pink and a black ground are also for the oil level switch, this truck is not equipped with.



While I am in here in the SJB, it is time to bypass the PATS control over the starter relay
This truck will have no PATS (Holley PCM) 07 Ranger PATS is part of the PCM and that went away







the starter relay ground control from PCM is right here, DB/OR
I will use a factory pigtail to create a new ground right near SJB




now the ignition switch has control over the starter relay

Alternator wiring was removed from engine, re-wrapped and then laid back in place.

One more thing to do to finish our 5.0 conversion wiring here at the SJB
5.0 battery harness leads for alternator charging wire and battery + terminals are the wrong shape to fit our 05 Ranger SJB



marked and carefully cut with a grinder, then file
Engine and truck were covered for the grinding event. These are soft metal? easy to cut
Also had to snip a little plastic


fits like factory

SJB is done...for now I may need to add some mini fuses as well as I install all of these electronics!!

Last edited on Mon Sep 26th, 2022 03:13 pm by Eddie Money