What will I need to "Swap to Powerstroke" - Diesel Forum

jds;kojdfkajdf;k · 10-01-2007, 06:23 PM

Will be picking up a 94' engine and tranny and swapping out my non turbo 91' IDI. What Parts do I need to do this swap? What are my speed bumps? Did anyone do this already? Will be happing soon, any help will be appreciated. Thanks in advance

AaronSEIA · 10-01-2007, 08:01 PM

Your gonna need everything that is at the other end of any wires on the engine, maybe some fuel line re-route. Not sure whatelse.
Aaron SEIA

**bugman** · 10-01-2007, 08:47 PM

As was said you will need the whole engine wireing harness includeing the PCM, along with a lot of wireing under the dash. I'm not sure if you can retofit any thing from your older truck to the new engine as far as wireing. Those that I know that have done it have had a whole donar truck to take apart.

Jim

jds;kojdfkajdf;k · 10-01-2007, 09:19 PM

Deleted

jds;kojdfkajdf;k · 10-01-2007, 09:35 PM

Well I will be getting the whole truck. Just wondering if it is more than I could chew on. Do wires have to be spliced, or do I just have to match up harnesses?

TERRCO · 10-01-2007, 10:47 PM

I've done this and it helps to have the donor vehicle handy.Mine was a 94IDI swapping in a 97DI.I don't know how similar mine is to yours but I believe between 91 and 92 there were some changes in the body/interior.I was lucky enough to have a wrecked & rolled 97' F350 4x4. Don't forget the IDM on the drivers side fender.Also dont forget a PCM bracket that goes on the drivers side if applicable to your truck.Don't forget the abs controller if applicable behind the glove compartment.As already said you need the engine wiring harness and in my case I took the harness starting at the battery terminals all the way to the fuse/relay box(under hood)Also you need the interior wiring harness under & behind the dash.One thing that you may want to be concerned with is if the truck your doing this to isn't the same cab style ie;SC, CC, RC there is one plug that will give you trouble on the drivers side kick panel.I left it unplugged and have had no issues.With the fuel lines I took one of the fuel pump assemblies out of the donor truck's tank and cut the steel lines(2) off the top of the assembly.I used these ends to connect my existing lines to the DI's fuel lines.You will see the DI has those push lock fittings or whatever there called.Also your windshield wiper motor connection might be different.Mine was and I just used the donor wiper motor instead of trying to figure out the wires.As far as your question if wires need to be spliced, in my case it was all plug as you go.Your truck might be different.Also if the PCM has been sitting a long time I was told that it has to relearn a few things.I don't know how true this is but I had an issue when I first got the truck going with the pedal.When you first started the truck for the day the pedal would not respond when you pushed it.I had to push it 2 or 3 times before the engine would rev up.After that it was fine the rest of the day.After a few weeks of this the pedal was normal.Like I said I don't know if there is any truth to that but that is what I was told by a ford dealership mechanic.Also my cruise control went thru the same process.After two weeks or so it was fine.I'm remembering things as I type.If you can replace the large plugs on the ends of the heads.Mine showed a small sign of a leak and my friend who is a mechanic told me I should fix them before I put the engine in.But as usual I was stubborn and in a hurry.The small leak became a big leak after 50,000 miles.They are a pain to change in the truck.If you can, swap the battery trays, radiator,washer fluid tank and the coolant overflow tank.This will make connections alot easier.I'm sure I'm forgetting alot.I did this back in 99'.Well my DI has 308,000 miles with no problems other than the usual,cps,water pump,gpc,???? I'll check back on this thread as soon as I can or pm me any questions.Hope this helps.

jds;kojdfkajdf;k · 10-02-2007, 12:30 PM

Thank you Terrco for all the information on this switch. Sounds like a bit of work, but I am willing to tackle it. I will use your post as a guide as I change my truck. I will reply back on this weekend or next week after I spent some time working on the conversion. Thanks again, Steve

BKB · 10-02-2007, 06:32 PM

Well i converted a 1997 gas to powerstroke so my list might not be 100% for you're application.

ECU
IDM
Under hood fuse box with wiring harness
Engine wirng harness
Down pipe
coolant expansion tank
fan shroud
rad
rad support
repining wires threw cab bulkhead
adding diagnostic port in cab

AaronSEIA · 10-02-2007, 06:55 PM

Another thought I just had. This would be a good time to take a hard look at the donor engine. Pan gaskets, oil cooler gaskets, glowplugs, fuel pump and water pump all have to be easier to work on with the engine on a stand. Might want to take some extra time and $$$ and invest in some new gaskets, etc.
Aaron SEIA

brown 4x4 · 10-02-2007, 09:34 PM

I worked on a 90 converted to a 97 Powerstroke. In addition to everything listed, I noticed a PSOM hidden under the dash, probably so the PCM can get an accurate speed signal. Cruise buttons were also mounted on the dash. It used the 90 ignition switch and even WTS light. I wish I would have had more time to look it over closer.