S197 CaptKaos' 2011 S197 LS Swap Build Thread Profile - S197 Mustangs

[Captkaos]

Friday May 19th 2023: Piping showed up so I test fit it in the car using some left over hose. Got it marked and dropped it off a a friends to get it TIG welded.

 

[Captkaos]

Sunday May 21st 2023: Got the welding turned around pretty quick so I rolled the bead on both ends

 

[Captkaos]

Tuesday May 23rd 2023: Picked up some hose for the heater core and then went to mocking in all the cooling lines to make sure everything fit as expected.







Once I got everything sorted I secured everything down. I cut the ends off the factory hose and used them to connect the new heater hoses.

 

[Captkaos]

Wednesday May24th 2023: Had to clean up the garage before I got started this evening. Once that was done I started routing the Terminator X wiring harness. Went to bolt the intake on and couldn't find the manifold bolts so put some on order.

 

[Captkaos]

Monday May 29th 2023: Intake bolts showed up so I got the DBW TB bolted to the intake and got the Intake bolted to the engine (temporarily) and ran through some harness routing scenarios

 

[Captkaos]

Thursday June 1st 2023: I got distracted from the wiring as I ordered some new tape but while I waited I played with the idea of using the factory airbox. Eventually it didn't make the cut.

 

[Captkaos]

Saturday June 3rd 2023: I got the drivers side Truck coil mount installed and checked the intake and found a problem.



The Fuel line runs right into one of the coils



Removed the fuel line and then tweaked it some





installed the AN fitting and verify the fit.





Jumped back to the wring and found this lovely idea. Why use the grommet not 3" away when you can just poke the wires through? Thanks Audit installer...

 

[Captkaos]

Sunday June 4th 2023: Connected the fuel supply line and connected all the Terminator X, and Current Performance Truck TBI, Ford Pedal to Holley, minus the power harness and threw in the Factory Mustang power harness to sort out the mass of wires I need to route.
There are several wires I need to sort out and the main Terminator harness had the DBC connectors for TPS and IAT + the Fuel wires I will never use.. Plus the factory harness has the trans control wiring and the EPAS wiring which I am replacing.

 

[Captkaos]

Monday-Wednesday June 5-7th 2023: OCD got the better of me as I HATE wires in cars that go nowhere so I de-loomed the Terminator harness and removed the TPS, IAC and the Fuel sensor. This took 2 afternoons.



2 nights later this is where I ended up. Top left of the picture you can see all the removed sub harnesses. Once I had it pulled all apart I went ahead and got some Tesa Underhood tape on the way along with some aluminum heat tape from DEI.

 

[Captkaos]

Saturday June 10th 2023: Dug into the Ford power harness. Spend the whole day removing all the tape, insualtion ect and got the factory ECU Powered EPAS and the Transmission control wiring out.



The simplified harness is on the left, what I pulled out is on the right.



I also ordered parts for the Intake since I won't be using the factory Airbox.

 

[Captkaos]

Friday June 16th 2023: I had a lot going on the past week but the Intake parts showed up along with the Holley 12.3 Dash that I have been trying to talk my daughter into.

 

[Captkaos]

Saturday June 17th 2023: I didn't get any pictures after this where I was mocking the Holley 12.3 in the car but needless to say the factory cluster probably wont be going back in after the surgery.

 

[Captkaos]

Sunday June 18th 2023: This is the pieces I am potentially going to somehow modify from the Factory Cluster housing which were permanently removed from the cluster.



You can see from this angle the gaps/open area that I am trying to cover up.

 

[Captkaos]

I apologize in advance for not keeping up on the progress but I had a lot going on this past couple months on top of my day job changing directions. With that said, many posts coming to catch me up to today.

Weekend of June 24-25th 2023: Most of the progress that I have been making is related to reading wiring diagrams and tracing and labelling wiring. This weekend I was researching the C146 plug wiring (connector to engine), C110 plug wiring (charging/AC/start) and the ECM Plug wiring.

 

[Captkaos]

Thursday June 29th 2023: Finally gave in and pulled down the AC and removed the factory compressor. I also started laying out potential Terminator wiring routing and placement along with playing with Air intake layout..

 

[Captkaos]

Tuesday July 4th 2023: Finished up the re-looming of the power distribution section along with the Holley harness.

 

[Captkaos]

Sunday July 16th 2023: Finally decided to put the ECU inside the car and started the process of routing all the wiring. Pulled the passenger side inner fender to get access to the body grommet. I did have to tweak the brace to firewall opening some to get all the wires in which were ALL of the Terminator + the EPAS wiring.



Had to install/remove the battery box a few times to make sure I had enough clearance for all the wiring but finally got everything like I wanted. (hindsight I should have not committed to taping this all up and closing it up)





Once inside I just had to sort out the lengths and get them all to where they would route and reach the location above the glovebox.

 

[Captkaos]

Tuesday July 18th 2023: All of the wiring is now passed through to the outside so I got the gromment back on with some slight modification.


Installed the battery box one last time and then taped the wiring together to bundle the looms together





Once I was satisfied, I sealed and taped the wiring and grommet. Not pictured is where I spent about an hour pulling the ECM apart because I saw that people were making integration harnesses with the factory ECM plug. It was a fruitless effort since it is soldered to a circuit board.

 

[Captkaos]

Thursday July 20th 2023: Hard to see in the picture but there is room under the Airbag as long as you remove the tabs under it. So with that said I proceeded to remove the said tabs and tweak the supports to make some room for the ECM.



Once placed above the bracing I started rough sorting out the harness routing from the firewall up to the ECM.





Also routed the DBW harness along with the dash harness over to the drivers side.



I also sanded down the back of the dash to make more room for the Holley 12.3 dash.

 

[Captkaos]

Friday July 21st 2023: Still fitting the harness above the glovebox so it can open/close without issues.



Started consolidating the power, switched power and ground wires along with the brake wires so they can be routed.


I also started on the Current Performance DBW setup, which is for a GM 6 pin. I use these often and after looking at it versus what I have comparted to what Current Performance supplied I found I needed to switch the following pins to match what Ford shows for the pedal



(Hard to tell, but...) Still tweaking the dash for fitment but was getting really close to done so I put something over the protective film after sanding it down some more.



Started sorting out the routing and position of the AC module and all the other harness and wiring connections under the hood.