i spent a day or two trying to get my fans working off the ecu but i could only get them to work on low speed and they would not turn on when i switched the aircon on.
so im still using the davis craig switch...

ive since changed my ecu so i might try hook the fans to the ecu again..

OK - List of parts needed to install an EL Engine into a EB Non Smarlock Car.

EL Engine - including air filter box and intake piping/brackets etc - everything
El Engine Accessories - Pwr Steering box, alternator, A/C Compressor - All of it
EL ECU
Smartlock Bypass Module
BBM Solenoid and associated Vacuum Hoses
Knock Sensor plug and wiring
EL Throttle Cable and pedal - The pedal ratio is different to the EB
EB Manifold Loom modified for use on the BBM
EL Map Sensor
EF/EL Heater Hoses - both as they are different to the EB
EB Engine Mounts - use yours - one of mine was broken lol
EF/EL Radiator - the bottom hose is smaller than the EB
EL Lower Radiator Hose
EF/EL Thermo Fans - Davies Craig Thermo Switch
Exhaust Manifold Gasket - Only needed because I used my extractors
Exhaust Flange Gastket - get the correct size
Engine Oil and Filter - 15w 40
Transmission Fluid - At least 5 litres
Power Steering Fluid
A good selection and quantity of hose clamps
Radiator Coolant

Oh and a sump gasket for when you squash the sump - not recommended

I think thats about it. Anything I forgot PaulMac?

BenJ

jesus mate no wonder we didnt see you on sunday up the coast

at least you wont be covering me in black oily smoke next time i bring the louts on a cruise

Well done Ben and Paulmac. Sounds like it turned into a much bigger job than expected.

Paul,
It was just a job where Murphy's Law applied.
Every nut and bolt seemed to be stuck or wouldn't fit back where it came out, especially on the damn Pacies and cooler lines and we couldn't risk stripping them.
The torque converter, well they either go straight in or they don't, this one was particularly obstinate and the resulting efforts led to the mistake which slipped the jack into the sump. Unnoticed in the dark it became a problem that stopped play.
The engine had fired up fine and by rights Ben should have been on his way 8-10 hours earlier to rejoin his family function.
There were a few small items that everyone else had failed to mention [or we had not examined closely enough] that caught both of us out, like heater hoses. This led to delays of up to an hour a time as we chased around to get them, or fabricated a fix. Then the sump gasket, another 40min trip.
My forgetting to pick up the accelerator pedal and cable with the engine cost nearly two hours and in my rush to leave I stumbled over my old block and gashed/gouged out my right leg. A quick fix wasn't good enough to stop the [copious] bleeding, so I had to turn back for treatment and my wife took off to Minmi to pick it up, a very big thanks to Darrell who had it ready for her.
Bless Panadeine Forte too.
Even without the benefits of an enclosed workshop, this job should never have taken so long and it wasn't botched or incompetent work, just all the little hiccups happened at the wrong time for Ben to get away quickly.... Murphy's Law! I've yet to meet the mechanic who hasn't had one of those jobs.
Another install could go as smooth as silk, especially now Ben's writing up the pitfalls he found for others to avoid. He put in a lot of thought and showed great skill and patience in overcoming an unfortunate series of events which [we hope] may not dog anyone else.
Those unfortunate events aside, this is a very good and economical way to upgrade an EA-ED to BBM, serpentine, fans, alternator etc.
Most delays were not in the actual removal or installation of the engine, none at all with the engine as supplied, mainly in just clearing the way to do it.
When my wife's Fairmont is done soon, hopefully with an engine from the same place, we'll have a direct comparison and will be able to put all this down to unfortunate experience, or evil spirits! [my pick] LOL
From what Ben tells me the car is going really great and that's the main thing.
Cheers,
Mac.

Well done boys - great result.
Yes, even doing a BBM conversion on an XH, even though most of the additional gear is there, there was still "little" differences that needed to be fixed or changed - fuellines, accel pedal height, etc.

great stuff guys! well done

Well it didn't take long. The first mod to the EL engine has happened.

Advice from mates indicated that there is some worthwhile gains to be made by removing the restrictive exit from the EL airbox. I don't know what Ford was thinking but it appears there is quite a backwards step in airflow from the EF to the EL.

This is the EL exit pipe



And this is the EF exit pipe - quite a bit larger



And on the inside, there is quite a substantial difference in the design.

EL - internal



EF - internal



The trumpet design according to flow tests by Autospeed magazine flows around 18% better.

So to get the air from the new larger opening I went to Supercheap and purchased a 300mm length of 76mm ID Aluminium Pipe. I cut the end off at around 30 degrees and installed it.

Original EL Intake



Modified EL/EF Intake





Looks pretty darn good I think. One other mod I had to make was to add two spacers under the plastic cross piece over the BBM manifold to lift it all up around 6mm. This is because the bottom of the new pipe was just touching the top of one of the suspension bolts. I have also cut some extra holes on the passenger side of the lower airbox to improve airflow into the box.

Now the big question. Does it make a difference?

Yes. Especially at part throttle in the mid range. There is a really noticeable improvement. In standard form, the car sometimes felt like it had a flat spot or hesitant under normal/light accelleration. If I gave it some more throttle, zoom, away it went. With this feeling has gone away. And with the stronger mid range now traction in the wet is an issue. I must get my LSD fixed

Cheers to all

BenJ

Looks great mate, I also have this sort of thing to look forward to in the next few months or so but I am going from EF to EF-L engine swap so I hope that should be straight forward but we all no how it go's, something will pop up. Hows the power difference??

The power difference from an old but still strong EB to a healthy EL is quite surprising. The real difference is in the delivery due to the BBM.

Just do all the research you can. Do as much pre swap stuff as you can, and accumulate all the extra things you need.

Good luck

BenJ

I think I might do this, already have the EF airbox and piping here, however I'm not sure if I should get some corners etc and replicate the EL style or what... simply because I don't want to pay $30 for some plastic from the wreckers only to have to get some pipe anyway that mates the airbox to the rest of the pipe.

What setup are you running and which inlet manifold?

BenJ

EF setup, bbm, EB Falcon

looking realy good there ben!

i got a alloy pipe to do the same thing
but unfotunatly as i have koni adjustable shocks the adjuster sticks up about 20mm and the damn pipe hits so without bends it doesnt work to well for me....

fit a BA intake and will clear the shock bolts......

Last edited by FordFairmont on Mon Mar 10, 2008 9:13 pm, edited 1 time in total.