1997 Mountaineer 5.0 for Coil-near-plug swap

[ATPCR]

The wideband AFR gauge/O2 sensor kit should be here Monday or Tuesday. After trying to start it but no fire, the injector noid light wouldn't light. I changed to another camshaft position sensor, the noid light worked as well as the inline spark indicator light. After building fuel pressure, the engine fired. So far it has idled only for about 30 seconds twice. The tach is not working as well as the start circuit has an open short or the digital range transmission switch is not calibrated. The rh exhaust manifold donut gasket is the wrong size and leaking. Transmission engaged. Just a few more things to wrap up before a test drive including installing the AFR gauge. I wouldn't be surprised if it is running a little lean after being warmed up. It is a 4.6 tune running a 5.0. But maybe the PCM will adjust to its feedback and run about right. We will see.
ADDED Sept 28th: The DTRS wasn't snapped in good. Starter works at the key.
Tachometer. The 1997 Mountaineer has a tachometer that is wired to pin #48 in the original '97 PCM. The 1999 Crown Victoria does not have a tachometer. In its PCM, pin #48 is not used. I would like to come up with a way to have a working tachometer.
I'll be looking at the exhaust leak tomorrow or Monday.
ADDED Oct 1st: Monday the AFR gauge kit showed up. It will be installed today.

Also, most of the hands-on time was spent disconnecting the rh manifold to flange connection and reconnecting it. The working space for this is very tight in the Ex/MM bodies. I assume it is the same as it has to do with the small Rangers. I got another set of eyes to look at the area of the leak. I couldn't see it but all across the bottom of the rh 1977 Mustang II rh side exhaust manifold is not sitting down against the exhaust ports properly. I'm sure that those of you that have been around 4R70Ws have seen the big square block nubs on the side of the transmission case. The nub is holding the manifold from sitting against the cylinder head properly. Hopefully the Sawsall will fit up in the tight space to chop it off. The working space is very tight and right next to the dipstick tube for the transmission.
Pictures will be added later.

[BOOSTEDEVERYTHING]

Why not just use the explorer manifolds? That would solve the fitment issues without having to cut anything.

[ATPCR]

The twisty Explorer manifolds and the TM Headers patterned after the stock manifolds interfere with the 7.3 coil placement and brackets. Someone could remote mount the coils and be able to use the stock or the TM headers. I have Mustang on the mind with the current coil placement. This Mountaineer 5.0 project is just to prove that a 5.0 c-n-p ignition system will work. I started this project years ago before I found this site. The second 5.0 will be using the 2003 pcm that Michael recommends along with other recommendations on his site.
I had some headers picked out from Advanced Adapters, but they don't make these anymore. Originally for Ranger V-8 swaps. I'm looking for a set, even used up ones.

I took care of the transmission ear today. I ended up cutting off half or more of it.
Square nub in the dark left side of pic touching manifold.

Now the manifold sits up tight. The M II rh manifold is the only
Ford manifold that will fit in this tight space. Old 1965 Mustang HiPo manifolds may fit too.
1977 Mustang II V-8 rh exhaust manifold pictured below.

1977 mustang 2 rh exhaust manifold.JPG

(7.69 KiB) Not downloaded yet

I'm not sure why the picture didn't load.

[ATPCR]

I somewhat have the engine running. The manifold is not leaking at the head but it is at the exhaust flange. This will require an exhaust shop to fix.
I can understand that a leak like that could keep from running correctly even in open loop? That is a question. The AFR gauge is all over the place but occasionally it will read stable for a short time.The throttle doesn't want to rev up when giving it some peddle. If you let it sit and idle from start up, it runs well then it gets slower and slower to the point that you can speak "1,2,3,4,5,6,7,8" then it dies.
In the meantime, I can be getting the other PCM ready with CRAI8 I think it is. One of the YYA2 varieties, with the QH etc. I just wish it would run well enough to make it to the exhaust shop. The leak is one the passenger side of the engine. The wideband sensor is in the lh exhaust pipe about 24" downstream.
The biggest problem is it won't throttle up to drive it normal.
Also wondering once it does warm up, what will the PCM think about the rear o2 sensors not present. Will it just post a code but not run any different otherwise?

[ATPCR]

ADDED 10-03-24 @3:40 p.m. The 2nd PCM with the same ARA3 P 71 file runs much better than the first one. It can be brought up to a higher rpm and hold it there for a bit. So far idling, it acts like it is slowly running out of gas. There is a partial issue with the TPS. I have another used one at home. I know that it's best to use new parts but the have to be tested too.

Question for Michael P. Which of these catch codes/versions would be best suited for the 4R70W?
JJV1 3.8 V6 manual mustang
DDM1 3.8 V6 automatic mustang
KYC1 4.6 GT automatic
FHA3 4.6 GT manual - Emissions Exempt
BAI2 4.6 GT manual - Cali Emissions
AOL1 4.6 cobra
VTC2 - grand marquis
YYA2 - crown victoria 3.27 gear police
FLC2 - town car

ADDED 10-04-24 @3:38 Project on hold. The 2nd used TPS in worse shape than the 1st one. The new genuine FoMoCo TPS is on its way. TBC.
ADDED: 11-01-24 2 weeks ago, I replaced the TPS with a new FoMoCo one. Short throttle revving is better. I have not been able to get the truck back on the four post lift to remove the fuel tank. The old fuel pump is either going out, or a possible split rubber hose above the pump causing it to push fuel out back into the tank and result with low fuel pressure. I will be checking the fuel filter too. 4+ years ago when I had a partial PCM failure, I wasn't having a fuel delivery/pump issue. Two separate fuel pressure test gauges were used to confirm low fuel pressure. The pump seemed to work fine when the last 2.5 gallons were removed. I can imagine the rubber connector piece of hose drying out and splitting as it sat there in an empty tank, but this is just speculation. I won't know exactly until I remove the pump/sending unit assembly and check it all out piece by piece. Target date for driving is Christmas break.
ADDED:12-08-24 Fuel pump access hole cut. I decided not to drop the entire fuel tank. This is a common 1995 to 2001 (generation 2) Explorer/Mountaineer modification.

Access panel cut and fitted.

ADDED:12-16-24 New fuel pump assembly on the way.

[decipha]

instead of editing the post its best to reply

rear o2s doesn't affect anything just sets a code

any of the automatic cals will control a 4r70w without any changes needed no problem

[ATPCR]

I was collecting up info etc., in the second post dated 10-02-24, while working out two significant issues. A leaky Bosch injector and a significant exhaust leak. I go tomorrow morning to pick up rh exhaust manifold that had to be surfaced and then go by an exhaust shop to make a 12" long down pipe. Last Saturday, a new Bosch fuel pump cartridge was installed. Fuel pressure reaching 40.5 and bleeding off. Confirmed with a Marshall fp rail gauge and a MATCO fuel pressure tester. #7 spark plug looks washed. Very recently purchased reman Bosch set. I will know more after flushing injector both directions. Maybe a little piece of EDPM from making the braided fuel lines. I won't know until after cleaning.
Our shop is closed this week due to extremely cold weather. Currently no running water. I still have to remove the upper plenum to get to #7 injector.
Can't run the shop (open flame) heater when working with gasoline.
Very at the moment reading your tuning document and I have TunerPro plain open working with one of the YYA2s. TunerPro plain has the search feature. I have a list of questions growing from going parameter to parameter. Also looking up acronyms on google. (i.e. ford eecv sp**) I'm not a tuner so I will be asking a tuner questions.
The rear O2 question was asked October 2nd before I made the post where I have a collection of regress and progress. In my version of YYA2,
I have turned off the rear O2 sensors. I'm just getting started with this part.
Thanks for the answer on the rear O2 sensors and automatic calibrations.

[ATPCR]

~ 3 or 4 post up, I edited into an old post as I'm trying to get this to the finish line. Spare you all the week to week of no forward movement.
I've recently installed a 2nd fuel pump. Just a cartridge this time.

I had two exhaust leaks to deal with. The first, a warped antique 1975 Mustang II V-8 passenger side manifold. I had it surfaced.

The 2nd leak was from me trying to adapt 2.25-inch exhaust to a 2-inch manifold. I had a new piece of two-inch downpipe made.

Soon I will get this part back together. I also have a #7 fuel injector sticking open. I'll be required to strip the upper plenum and related parts to get down to the fuel rail and injectors.

[ATPCR]

now I've been working with the YYA2 version of CRAI8. Remember, I'm a novice and don't claim to be a tuner. It doesn't have anywhere near the number of parameters to it that 03-04 RZASA bin file and definition file that I was first using to learn my way around TunerPro. Is that because from 1998 EEC-V programming grew to be that much more detailed by 2003 or that the RZASA strategy has been more intensely disassembled and defined? Michael, how did you ever disassemble all of that in RZASA?
Now to the parameter questions that have come about as I have worked my way halfway through them. Remember
Here are some of the scalars.
BIN_CHIP_ID is set at 19A8. Is this the code for 1998 Crown Vic?
SP**SARCHCHG-CID engine size, does it need to be changed to 301.5 cubic inch dis?
HEGO_CONFIG number of rear hegos I changed to 0 for none
SP**Global fuel K -constant is currently set at 19.441. I'm reading in your comments in the open files in TunerPro and your tuning documents to change to 30
SP**ALOSL-LBS/HRinjector low slope. Parameter comments are referring to high slope. Is this correct?
VID Octane (FNOCETEOL) does it need to be changed from 255 to 82 for 87 octane fuel?
OS_PULS_REVOSS Pulses Per Rev. Is set at 6 for AODE/4R70W
FPUMP_FREQ fuel pump frequency (return) Is currently set at 10, should I change it to 60 for a return fuel system using a regular relay?
There will be more questions about additional ones later.

[ATPCR]

This 5.0 engine etc. facts.
5.0 w/4R70W/3.73 gear ratio with 28.9" tires (724 revolutions per mile)
19lb Bosch fuel injectors with a return style fuel system
65mm throttle body
65mm MAFs
EGR delete
rear O2 sensors delete
87 octane 90/10