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2.9L w/ MegaSquirt to 4.0L w/ Ecumaster Black and a Turbo build

konrad911

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Yeah, I know... This is not a Ranger xD

Anyway the short story of this car is:

1. I got it in 2001 as my first car ever. Had to do a ful restore on it. This was 1.6L inline 4 with carburettor. Deamon of speed xD
2. I swapped the 1.6L motor with 2.0L and changed also gearbox to 5 speed manual.
3. I changed brakes - rears from drums to vented discs, fronts from solid discs to vented discs with bigger diameter and better calipers.
4. I changed suspension - coilers on front and single leaf springs on rear.
5. I changed the stock 2 barrel carburettor from FoMoCo to 2x Weber IDF 40 - magnificent sound, good acceleration, unacceptable MPG xD
6. I changed to 2.9L motor with MT75 gearbox (I think this was 2007). This required some cutting and welding to fit the tranny and radiator.
7. I changed EECIV to MegaSquirt 2 (this is 2012) willing to turbocharge the engine and later I changed 2.9L throttle body to 2.8EFI one (bigger diameter).
8. I bought Holset H1E turbocharger and put it on shelf
9. I bought external oil cooler and put it on shelf
10. I bought few other things and put them on shelf
11. Before turbocharging 2.9L I bought 4.0L and put it in my garage (2-3 years ago)
12. I sold the 2.9L with MegaSquirt few weeks ago to a friend
13. I removed the engine from the car (last weekend).
14. I will build a decent, turbocharged 4.0L - that's the plan xD

As of the plan, things I'm considering / already doing shopping is:
- update the value springs with dual Crane Cams setup
- replace the springs on the cam followers shafts with aluminium spacers
- replace the crankshaft with late 8 rod to flywheel one (DOES THIS MAKE SENSE?)
- replace the flywheel and clutch with the bigger one from SOHC (DOES THIS FIT P'N'P?) or a 2.5TD Ford Transit (it utilises same clutch as 2.9L/4.0L OHV but flywheel is 8 bolts - only verified by my via photos, not measured).
- Drive By Wire Throttle body from Mustang GT/F150
- Standalone management (Ecumaster Black)
- Coil on Plug
- SFI (adding cam sensor from EECV)
- Intercooler
- External oil cooler
- Holset H1E Turbocharger
- Custom Exhaust and Intake
- All other things that will come up...

95% of the works I will do by myself. I have an old school lathe, mill and other tooling. I can weld stainless and aluminium.

What I lack is TIME (and money to some extent), so this will not be a quick build, especially I don't cut corners.

And I will certainly need some help in sourcing parts I cannot find in Europe for the engine xD
 

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superj

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sounds like it will be awesome
 

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I really like the body style and the direction you're taking this build. I'll be watching and learning.
 

konrad911

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Thanks guys, I was hoping to learn from you, not the other way :D

EDIT: Just ordered the 97JM-AC crankshaft from UK. Keep fingers crossed this will work out for me :D

The description of the crankshaft as advertised, seems solid:
THE CRANKSHAFT HAS BEEN CRACK TESTED AND BENT CHECKED FOR ALIGNMENT
FULLY RECONDITIONED CRANKSHAFT STANDARD SIZE MAIN JOURNAL AND STANDARD SIZE BIG END JOURNAL
THE MAINS AND BIG END JOURNALS HAVE BEEN EITHER REGROUND AND / OR MIRCO POLISHED TO MANUFACTURERS SPECIFICATION
THE CRANKSHAFT WILL BE DIPPED IN ANTI RUST SOLUTION

I'll post photos when it arrives. Confirmed by seller it has 8 bolts for the flywheel :love:
 
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konrad911

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So as per the book about building performance 60 deg V6 I'm going to replace the valve springs.
Crane Cams I think was taken over by comp cams?

The book lists (Crane Cams):
99858 inner springs (there is mistake in the book claiming it's outer)
99834 outer spring (there is mistake in the book claiming it's inner)

I found 99858 on eBay - set of 16 with one broken for $14.99 + shipping :D
I found also Comp Cams retainers that seems to fit my application on Amazon 775-16 for $33 + shipping (arrived today)

I cannot find the 99834 outer springs nor their specs though....

Anyone has Crane Cams catalog (maybe printed one?) that lists specs of these springs, so I can figure out the 99834 replacement?
Or maybe someone has 99843 springs for sale???
 

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konrad911

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So I have both engines on the stands now.

The 4.0L airbox/intake looks massive compared to the European 2.9L.

The nice black aluminium rocker covers come from European Ford/Mercury Scorpio(Ford Granada in UK).
These bolt straight onto any of the V6 family (2.0L-4.0L), but for the 4.0L I see that the stock rocker covers have bends around the injectors and to fit there a small amount of edge of the aluminium rocker covers must be ground off.

For me I think this will not be needed, as I will replace the injectors with newer type ones that are thinner in that area.

IMPORTANT: The surfaces do not mate 100% with 4.0L heads (due to those bends), but there is coverage, so the surfaces should be ok to seal. On the other hand, these usually leak on the bottom part anyway :)

I did some investigation regarding flywheel and clutch. It seems there is 10.125" diameter clutch that was fitted in the 1997-2000ish models (AMS 07-139 available at rockauto.com for $170) that bolts on to any of the manual 4.0L.
The earlier clutch has ~9.5" diameter and the spring tension is slightly lower, so the newer crank with 8 bolts for flywheel and newer clutch seems to be a perfect match to an upgraded power engine.

I did compare the tech data about the 8-bolt flywheels, and these are same as the earlier ones with 6 bolts with the respect to the numbers of bolts :) (296mm outside diameter of the toothed ring and 138 teeth).

So when my crank arrives I will shop for the flywheel and clutch as well.

I was hoping I could do it rather quickly, but it seems as usual I will do it the right way rather than quick.
 

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gaz

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Konrad,

My cam will be a custom grind as recommend by my machinist; it is slightly different than the big Comp Cam grind, to compliment the auto transmission and my engine's flow characteristics. When he did the valve job he was able to source some "jobber" dual springs for older Ford V8's that are perfect. I believe have the spring and cam grind info if you happen want it.

Those valve covers are just dog-gone CANDi!
 

BlackBII

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This is going to be awesome!
 

konrad911

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Gaz if you can check which Ford V8 the springs come from that would be perfect. There is almost nothing in the catalogs for the V6, but V8 is a different story.

For the camshaft grind - there is a guy I’m in contact with here in Poland that did 4.0L biturbo. He’s above 400 HP at crank and said the 422 comp cams added only few HPs in that turbocharged application compared to stock cam. Not worth investing in. Much more he got from porting the heads.

Which brings me to another topic to think about. Late heads had smaller combustion chamber, I have early heads. To compensate smaller combustion chamber Ford changed pistons to the ones with a bigger “bowl” (sorry guys I’m not native :D) to keep the CR same.

I’m just thinking about finding a set of late pistons to lower the CR, which should be good for the turbocharged application…

Anyone knows if other than that these will fit right in?

Just an idea while I’ll be there anyway due to the crank change.
 

superj

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bowl is fine for what you said. i think the term used here is dish though so bowl works. but someone else probably has heard another term for it too
 

konrad911

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As everyone likes pictures...

These are early and late pistons - not that hard to spot the difference :)

And the Capri going for a "sleep". I'll cover her in a cloth later. Just washed before covering.
 

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gaz

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@konrad911 ,
Since you are using 94 spec heads you can use either of the three 4.0l OHV pistons.
91-94 pistons, small dish.
95-97 pistons, bigger dish lower compression ratio.
98 spec pistons, same as 95-97 dish but 50g lighter each.

For a forced induction build I would useing forged pistons, unless I was committed to less than 7lbs of boost but if you are going to use a stock piston then here is why to consider the 98 spec Piston with 94 spec Heads.
Screenshot_20220319-031128~2.png
 
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gaz

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4WD
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Ranger 6", BII 4"
Total Drop
Ranger 5sp, BII A4LD
Tire Size
Ranger 32", BII 28.5"
@konrad911 ,
The springs I'm using for the my 4.0l are "Engine Pro competition", Nitro Black Dual, Street/Race, part number:

02-1024-16

They were sourced by my machinist from the "Engine Performance Warehouse". Thinking back, it took him awhile to find these and I believe they are actually for an older Chevy V8; this complete V8 set was $75.
Screenshot_20220319-033158.png
 
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gaz

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2WD / 4WD
4WD
Total Lift
Ranger 6", BII 4"
Total Drop
Ranger 5sp, BII A4LD
Tire Size
Ranger 32", BII 28.5"
Cam grind is as follows:

• intake: 0.498 @ 210°
• exhaust: 0.474 @ 216°
• 112° lobe separation
• cut with 4° advance

$170 plus 2 way shipping.
 
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