Just wanted to document (so far) what is generally missing from everyone's ZE installation list (reminder - We have a curved neck ZE from an automatic trans installation, LSD trans, and a KL36 ECU):
1) The engine mount behind the timing belt cover from the K8 needs to be transferred to the ZE (remember I've got a curved neck one so this may not apply to all ZEs). The ZE one can be made to work but the threads on the fasteners are not low enough to tighten the nuts and I wasn't willing to take the risk of the mount not being in the exact vertical orientation as the K8. This was a pain because I had no plans on removing the timing cover due to the low mileage on the engine received. It was fun - I can't imagine replacing a timing belt with the engine IN the car.
2) Reverse location of the knock sensor (grey connector with orange inside - NOT the crankshaft position sensor) - need to remove the IM to do this - thanks to wytbishop to point this out. Again, a pain but very useful. Love getting those nuts out of the V6 valley when the fall - because you WILL drop them.
3) Unique to us was that the P/S pump pulley was plastic (cost save??) and cracked. The K8 had a metal one that we used, thankfully.
4) We decided to use the "new" power steering pump and the "new" alternator. We need to do the ignition wire FAQ steps as the alternator is the same as the Milllenia mod (thank again wytbishop). Just needed to swap the P/S pressure switch wire from the K8 to the ZE.
5) Swapped the coolant temp gauge wire from the K8 to the ZE so it would mate easier to the K8 harness
6) Reused the K8 fuel supply fitting to the fuel rail and removed the ZE extensions for the supply and return lines. Was able to use the return line form the ZE once the extension was removed.
7) For the vacuum brake booster was able to use a vacuum port on the driver's side part of the IM and swapped the rubber cap from driver's to passenger side.
Found an oil plug to fit the EGR port on the OBX rear header pipe - EGR is not on the ZE.
9) Cruise control went to a capped vacuum line on the driver's side of the IM.
10) No mods to the existing wiring - however we had to remove the harness tape, a metal mount, and a 90 degree plastic bend to allow the O2 sensor wiring to separate from the take-out for the two VRIS solenoid connectors. This added about 8" of length to the O2 sensor relative to the VRIS connectors - long enough to connect to the rear O2 sensor with no mods.
11) Throttle position and injector connectors went right on.
A note - I got a 6 port disty on this engine so the coil is integrated. While the unit looks different than the K8, the connections are compatible [update - no they are not - went back to the K8 disty to get it running - go here to see a comparison of the OBD-II ZE disty compared to the K8 OBD-I -
http://www.mx-3.com/phpBB3/viewtopic.php?f=15&t=70342!!].
Also bought new outer tie rod ends and new halfshafts. For now, we'll reuse the intermediate shaft and bearing from the passenger side halfshaft -seems like you can't find a replacement for that...[update - to see how I resolved connecting the LSD to halfshafts go here:
viewtopic.php?f=30&t=70010
So, it looks like the only remaining required purchase is an exhaust system aft of the Probe GT Y-pipe....I guess the neighbors will have to wait a couple weeks for that - he he.....
[update: added a custom 2.5" exhaust - resonator where the cat is supposed to go (its just a test pipe, right?) and used one Mustang muffler - plan and result is a stealthy exhaust for cruising with significant presence during "spirited" driving]
