It's all in & running now (erm, 2nd attempt was done at a mechanics after the first attempt resulted in mass coolant loss between block & intake lol), but the car is a dog:

* Idles a little roughly, and not in a "cammed" kinda way
* Hesitates on takeoff
* in neutral it seems to rev "slower" (wtf?)
* Sluggish acceleration (EA CFI, anyone?)
* Initially had a heap of steam from the exhaust, suggesting either some water/coolant crap left over in the bores or a gasket leak. Steam issue seems to have gone after a few drives, which gives me one reason to believe it may be the former explanation. Conflicting info is further down in this post

The ECU seems to be learning somewhat, as after approx 80kms of varied driving it's idling smoother, and the hesitation has lessened on takeoff. It was going through fuel like a clevo initially, but it seems to be improving now. It's still sluggish however and way below par compared to the HO it previously had.

The exhaust has a bit of a "fwapfwapfwap" noise coming from it on idle, sounds like an exhaust leak despite the exhaust actually being fine. Possible gasket leak from intake (somewhere)?

I'm temporarily running it with water instead of coolant to flush out any crap left over from the swap, then I'll get it pressure tested plus a full flush (replaced with coolant), but I noticed when I got home that the coolant reservoir was FULL, beyond MAX, and the water was boiling madly. It wasn't dropping any from the overflow however, and the temp gauge wasn't anywhere near high.

Despite the motor still being warm, it's been a good 90 mins since I got home and the water level is sitting back at MAX now (not boiling either, i'd be scared if it was).

The last thing I should mention is that I damaged an injector in my part of the manifold swap, I'll post up a pic to illustrate. The o-ring and its plastic backing is fine, and the jet/tip itself is fine, but the area of plastic highlighted has been cracked. I doubt this will have anything to do with it running like poo but I thought I'd include this bit of information.

Looking forward to your responses.

Cheers guys

-Dave-

 

 

Attachments:

cracked.JPG [ 20.25 KiB | Viewed 176 times ]

I've been informed that my problem is most likely (or at least *one* of the causes is) due to my EB EGR not matching to the Explorer intake, leaving a gap underneath.

I noticed when mating the two that the EGR did overlap a fair way on the sides, but it appeared flat along the top. Little did I realise that it overlapped even more underneath, creating a gap.

Shown below is the link offering a solution to my problem:

http://www.fordforums.com.au/showpost.p ... ostcount=5





Hopefully someone else will find this of use when they undertake this conversion. Cheers,

-Dave-

PS Thanks once again to NZ!

Have you tried it yet?

I'll check it out tomorrow during daylight hours & post my results. I'll test by stuffing a rag there first, then silicone.

Swapping to an AU spacer would be best however, and I may do this in the medium to long term.

Cheers

-Dave-

All fixed!

Yes use the AU spacer because the explorer intake has no EGR passage anyway. Therefore no point having the EGR spacer or coolant lines.
What catch code EEC have you got? You can turn off EGR with the TwEECer.

Pete.

G'day Pete

EGR inlet was blocked off to fix vac leak. Also (unrelated), the timing was way out.

In the long run I will obtain an AU spacer, but for now the EB EGR will stay.

I'll still keep a TwEECer in mind mate, and thanks for all your help in the past too.

-Dave-