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    3 views162 pages

    Montar Motor

    Uploaded by

    Andre Viotto

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 162
    TT Te WET De Ae % 2 ih 3/38 ee e AT Som a POWERPRO SERIES / How to Build and Modify FORD GO" V-6 ENGINES Sven Pruett it published in 1094 by Motrooks Internationa Publahors & Wilesaers, PO Bin 2.728 Fraps Avene, Ov, Sven Prot, 198 Alsight reserved, With he ‘seeping rie pssages Die pemeaworenareh pred witha pie wren ‘isso rom he Publier Mitr [teratonal is (eiled demark,rened ‘Te information inthis eck teue and vomplete to the best o aur edge recommendations Sn the prt ofthe auteor Photehr who sien dai ny Titi tnared in ennection sth the coo of thi at epic ‘Wo ognie that sme word, Jhedel pnes ad dengan or ‘tame, meatoned herein are the [rovers fh tademane elder ‘ae the for entistion parpves only. This ism an Motobons Intonation Books teal dicts Bat quant for industria ‘le prometiona ie. For details ‘rite a Speci] Sales Manas a “Library of Congress Catan Puente Date Prat he ow wore our Ford V8 0" cose Pr Insader nse eNostaeo1e "Antonie Mobee— Maintenance and yopa 2 Ford ‘torn LTT Si, Om the front cover Teabaespie oFRerdso WS easly eresed Sevres caret eee Sine okentemp sn an bd inthe Uta’ Stas Amesia Contents AAA IN Sear Appendix About This Book Dedication Acknowledgments Forword The Cylinder Block The Crankshaft and Connecting Rods Pistons Cylinder Heads Intake and Exhaust Systems Camshaft, Lifters, Pushrods, and Cam Drives Ignition Lubrication and Cooling Balancing Assembly Tips Suppliers List Index Ook AR 27 42 50 82 110 119 122 127 131 159 160 About This Book ‘This book was written in an ef fortwo provide the deit-sourelt fngine boiler with the informa fon neceasary to build a re Spectable Ford 60-dagree V-6 performance engine. Therefore, very attempt has been made a ‘void procedures nd parts Ua fro “eaote” oF prombravely x= pensive. Ite the satent of tio Fook to provide a detailed dex rptin of the modieatons and Drocedures that are within the Dedication It seams that when the time ‘umes to express our apprecle- thon fr the enormous meunt of Support that you receive from loved ones during the production of such a work, you never seem to be able bo quite convey just Tow much thos ery spa pos Ble mazn tou, However, atthe sk of faliag to acurataly and mpetey express my grate, racp of che average buildor The Rorsepower examples that are ‘deserted within tne bea by no ‘mean represent the maximum poser petentin! that i aailable From the Ford V6. That was not the intention. Te idea ist plore the potential of these en fines while mavntaining a high {evel of reliability, reasonable fost level, and relative ease of fanstraction, Readers wil find {hat most of the areas of engine Tam, at leat daty-bound to tr: “This book doen tomy wonderful family without whose Tove, eariag, patience, and sup pnt this entire project would snevar have been poe "To my wife, Mary, for your vndying fut fn me and prcions ‘your perpetual ps Aerscanding. To my beautiful Acknowledgments Spocial thanks to: Darryl Al smaty, Hank Dirtian, Lee Ham ‘Kins, Michael Tokarehie. David Miller, Wayne Gray. Paul Cun- ningham, Barry Calvert, Dave Grover. Phil Tley. Paul Mor- 4 phree, Randy Lyles, Franke Bafraek, Riek Reins, Tay. OF fenhausr, Ollie Morris, Mary Pructt, Bll Proott, Anneliese Pruett) Stephen H. Singletary, Steve tnd Labrie Moblenksmp, reparation that require very Epedalzed and expensive ooze doves (ike extensive cinder head porting, stroking, and to tn) have been avoided. These {pes of modifeations are very fiton out ofthe grasp of most en- ants et cae he a {areasze prtrmance al dea the ine before such modiieations are rouired ‘in daughters, Sibonet and De Slr, fr showing me the sean {ng af the Word “miracle” And last but not least to my parents, Bil ana Annee, he ave, fuldanes, suppor, and ch inapie ation to press an regardless, [Alm vet all you, — sven, ana 1884 Byron Frosch, Mark Cefourek, Uli Koclsh, Leo Capaldi, Gil Popitane. Dario Orlando, Mike Sender, The Block Shop, Mie High Crankohatte, and F&M ‘Auto Part Foreword First, tothe host of my knowl. ‘eg, a bon of thio nature docs Sot east ngpehor the Wor Asa Ford V5 enthusiast, you fre well aware tt almost every fepair manval devored to your particalar vehiele Includes an Fenaine repair section” or the ike: However, these sections «ften inva ony the most base ‘pair and rebuilding techniques. Thave aot yet sean a manual that wos able instruct an in ‘idual om how ta corre Use prob em areas of these engines oF how to significantly smprove their performance potential wath- ‘ot sacrieingveliabity. In Tact, in my experience, many of the techniques outlined in mest af these publications are outdated ‘rj lan wrong ‘Second, tho Ford V-6 is @ unigae engine. Although many ‘Standard balding todas ean find shosld be incorporated, {hore engines ae all of Ht pe” falas tht require very se- attention. Such “peculiar jos" have to be identified through long hows studing the ‘dynamics ofthese engines and hough goed old tral aud error (reads tying stu that events IW eaves ou up to your outlet in filary and busted parts, but riser tone theless). Many of yo Ihave probably already exper: ‘enced ot east a fow of Wace an foving tle gremlins, and T Sure you will agree that Life ‘would have boen Just fine had ‘ever come around tn 1 tise themeclven ope that this bale wal lp all who eon Sulit to avoid at leas 85 peeeat tf these potential problems ‘inal, the dition of on ‘enthusiast ie “One who possase ff eat event interest ‘Gtement” Perhaps @ more us [ind ourate defen of an au tamotive onthusiast would be: SOne who knows a tle about ‘Coerything but not everstbing bout anything” OF oare we all ‘eoow at lass one exception “hs someone who, cr wil aon hein possession of Ford ‘-degre V-8 you wil soon fd that you are whiqoe among your pacts Although the performance Potential of these htte engines fan be impressive, the perfor ‘mance parte seen i bleak at baat oy it you've gone so far a8 {buy this bok, yo are cbviow ly dodicated to Your pret and {ou have do snitaive to do as Well as vou are able. And once four fiends quit giving Yoo the abet Rha ae hope you willbe happy ‘withthe end rel af sour pro. Jee Furthermore, if afterall of ‘his, you sl in en yours t0 wale out into the garage on @ ‘Sotundayeftornoca, te up yeu? Finished projet, and eng i or the day, then you sre tre en Uhusiaee, and itis for you that ‘hina was written. The Cylinder Block For some strange reason, the finder block aften seems to {ak the consideration ght uch sn impor. element of @ per Tirmanee engine desres. A pr formance engine is very much Hike the human body. Te maa, cnhales, an eauies the proper ‘urement. fr aditons Fe ‘irs astro topping true {ire ao that team perform te Gatos ta fl potenti fa oe ‘ans, this dlegated te the Seleton. ina performance ene zine, tho cylinder block is the Siicins fe demands angosed Spon the engine blk are much Hee'same as those imposed en the humen skeleton, The block rust be strong and stable to ‘foe sufficient suppor. And it tvst be conditioned s0 a8 t0 er endurance and relly. Ta block fa not prepared cond toned! properly, the entre igne angembly fa subject too feta faite Choosing a Block. ‘Fecentily, all the Ford V6 Sosdegree engines share the fame bie Buk design. They all Incorporate fous main beating Saddles and four cam beering Sddls, thus providing exelent Tower end rat in moet app ‘tons, aur avallable chees {depend primary on your intend fed direction. Ifyou are purist {tnd are intareated in abeolae dluthentety then your deiion ‘mmplealay witb the engine that etme in your ca. However, sua are nat bound hy soe ee $ou have several options aval able toyou 20 ter ftemotve) ‘This engine is somewhat Fimited ‘ fn ts portormance potential. If you are limited so this engine, ‘lan'on relatively conservative Performance moaifeations. The ‘loki thin in cra etcl fveas hus ving tit" nae foro. If corto perarmance fs Sour goal 20hpr, hen step ub eithe 28 or 28 engine, ore tine you can expect to have prob Teme with relibiity. Consider alto thatthe 2.6 engine has ab Ssitcayne provision for hS- Arai alvetrain, Consaqueti, if'you really hate adjusting "abe thn hi ine Jamil yon ee slgatd tothe 26. keep the following Ving ia ‘iid hen preparing the @n- ‘der block. Pt donot bo this Beck ore tha 0.0900 ver” A few ast pubes have a= sted larger overbore (up Lo ‘06th, Th ano a god ie. ‘The qlinder vats are reaively {hin and ony wore than about 8 ‘dim everbore wil rest ta piston ring set pao snd Sverheating Furthermore, the 3 engin alters from ahr ex. treme block flexure when over- Boned Th xure can eos Se ‘er piston gallina event) iain failure de to the disor tion eested in he einer bores fand bearing sadist. Second, do te renee more than O10 fh Sr tho dose murtac, Ain tbe Acs ar too thin an they have Inge water passages on the Ibwer Sek surfaces tat are prone tong, Teo mech a {eval removal wil rele tn ‘roaged head gasket failures, @ problem in woe 26 engines a Wray. Because of these dravt Teck, recommend Ubt at east the Ber acon bie be cred fat al pone 28 ir (automatic! “This engine i 8 god cand date for perbormance mod ‘Hon, Ths Block bonof te from Soveal improvements thet are fie ea acing on nin the Baropean Gru {Sunny ear sores The advan tages ofthis block neue a ae ‘sBiaty heser overall earing ‘hah particle improvement i the nin wl Those modifeations virally Slant te hoc evar pro itn eaited with the 26¢ier torine, A Grenade inprovement In'pinton sing sealing reduced ston galing, and etter heat Scciptin ar ane nf 9 the trates to aeng thx lock foe pertmance purpores. Ane Dae advanta prea fer Shh prs aby om to the326. Tho 2 heron Fes are also mc moe abun {ine than the 3. Capris, Pin: {oe, Bobents, and Mestanzs, to ‘ine a few ere all aquped wiht 28 'Ar with the 2.6, there area few “ranimums” Wat mst not De'encoeded win building the 6! Fin, the mascmum alow fhe overbore In 0.040m, The tiuch overtore should be aveide (Shifat all posible. Amore rele Sie overbare mold be 0.0300 ‘The decks will safely neeept 8 (oa0tm maxiaom Cut, bat | frould takeoff only the mini ‘Hum amount. required to ighton each dos mis fll sf water passages thet redace {he ovorall deck lategry. This Shoal relate ay 8 deck ‘farpece isnot 5 common pr is Lasts engin, ke a 26 iter pradecescr, hoe me ‘hanical valvetrain, 28 iar ruck) ‘This engine incorporates one significant change that snakes i the best choice when boring the 2-8 bigger cam earings, This relatively minor ange allows eit move fattude ‘when choosing a casa. Cam {zandars have move room to play ‘vith larger base dele cama. Ad ditionally, the larger land Stronger) cam reduces most of the orston bar" effect expen teed in some extreme-daty 28 fnginos. Aside from the cam, however dhs engine ia essential ly the same he 28 automaive engine, and therefore allover: ore and deck miling hits sp plied to the automotive 28 en {ine should be followed. These Sgines mere selae in Ranger pekape and Bronce Tis through 186 2.0 iter ruc) Although the 29 resembles the 28 in appearance, i is sig: aifeantly different in design Fleet, the 29 retains the large cam bearing configuration, but thie engine uses hydraule val vetraia, This allows you to use ome nice cam profiles, include {ing some with roller ers, to Improve performance. Second, the camshaft drive hae been fonvertd to 8 more convention fl chain drive instead of the ‘sual tworgear drive wed i all, 200 and 28 engines, Third, the tytinder heads were completely Fedesigned, vitwallycliminat ing the problems inherent inthe 216 and 28 liter designs (more fn this later). Finally, the 29 ‘was only available as'an elec= ‘onieally fueLinjeted engine Although earburetar conversions are being developed, nothing is commercially available to complish euch a conversion. ‘Therefore, he fal injoation 2 tem wil Have tae sed in most appleations. As with the 23, the overbore should be kept las thon 0.040in- andthe deck rilinglss than 0.020%. ‘The 29 liter has many ad vantages, In fcr, if your poets are really deep, 4 set of four ‘alee Cosworth heads are aval fable in Burope, All things said fand dono, the 2.9 truck engine ‘Should be consideration for any engine expected to produce 235, trmore horsepower. 0itertruc ‘With the Introduction of tha Ford ‘Explorer eam the latest evolu tion ofthe Ford V8, the 40 Her, ual along the same lines as its ‘are cousin, the LD teri ually very simile. But ret as Sed, thats where most ofthe Similarity endo! The 10 Iter em. Joys numerous improvements in- cluding hydraulte roller cam- Shalt, erankcfive ignition, and fubie inches. The 4.0 was de Sized asthe standard engine for Ford's sporty veheles and a8 an opie i the Ranger Unfortunately, the practical ty for performance applications Father timited at this time 1a Hock tim, the engine # depen dent on & omplicated electronics System, and the investment re- ‘ire to convert i to something tore ronventional (read “aan sty ease yo uses Pook peso alerts hop mite xtacton ble") can quickly exceed the ‘budget of the average perfor ‘mance enthusiast. In short, un Tees you have a cnsidarale bud- set, dont expect tose very lly Performance goals or expecta: tons. On the plus sie, the 40 iter has s pretty good set of heads and, with a fair bit of ‘work, could easly produce able 200hp+ without requleing ‘an enormous outlay of mney. If ‘you desire in excess of 230hp, Fowever, expect « considerable Increase in expense as the re ‘qired performance components fire both rare and expensive. Ad though the block was subject to "grfleant weight reduction mes fares, the overall strength ss ‘ery god, This block wil safely Sscept a O.0d0in overbore and 02h of deck material removal Te appears that Ford intends to cntinue devalaping ew versions St this platform, so the futsre ‘may hold interesting things for ‘he performance mined, Disassembling the Short Block "The thing to ressember when Aigeeembling your short block torkeep everything organized. AS Take great care when removing the thr th feeze plug or tne ca cove Toor fezo py so at te sone tp ploy ino fe bot ree. tn ot be damaged: Never ave ot To help remove the rer oi gallon, ‘lise a poparo toch to haa he lea around me po oven Be a> {ey satay adhoc 5 you remove each component you ould mark it and its respective fasteners. Keep any reusable fas- tener and sal parts erganized So that when the time comes, yu will remember where they go. (Old butter tabs and eofee cans swore sonderfally when organi: Ing your fasteners. Mark the ld With the appropriate infrmation ‘and siore al ofthe containers in ‘bale place, Make sure that they Gon't get mixed up with other containers that belong to another project Before any work can begin, you mist strip the book of every. thing. However, before you tam ‘single nut, you mast mark all Df Ue reds snd main esp i they fre not so marked from the fact Each rod both halves! hold bbe marked according to iter pedtve eyinder number, Main taps shoul he marked aesonding fe eee Sees ee eee eke nas Soe eee eee Seon gicraia oe pea eas ee Serine etstae = epee eh Beste emg ees See Seen eer a eerie ee aie Se pease aoe a sae eRe Tiny. a toe eh ph et ey He outa Lee neers ise Serie %y The ci galery pug shout unscrew ay eS) urate ion ho An accurate inde bove meaeue ‘aoe wa be good eanduato fora Povomance reba 10 owe how ta use it le a machine ‘hop perform this task Cnce the block has’ been completely tripped of its parte, the roal work ean besa Cleaning and Preliminary Inspection "The Gest order of businoss is tosstablsh the “elldabiiy” ot ‘he engine. This begins by date Inining if the elindare have been Sverbored. Ideally, you should ‘Hart with 9 block with « stan dard bore. Using a veriee cali= per and shap gage ora elinder Bore gage, meusure Just below the esinder ge so that yu cat got an accurate reading. Ifthe Bok hts been bored ove than Doatin, stop where you aro and find ancther one. i you are blessed with @ standard bore blo, is Hime to (Once the block nas boon spe ‘Shek for “ung? around ine main boaing bores Brg asin ob Astermine the amount of wear in the eglinders: This fs best mea sored with a dial bore gage, ‘hough # snap gage and microm. ter are also acceptable. Take fhis measurement in the ridge aren as this iv the part of the Gjlinder that wearg the most This aren should be 0.015in smaller than the intended over bore size, For example, ifthe standard bore is 360040 aod you ‘would like to have it bored D.030in over (uo 4.690%), the ge aret must measube 467Sin tf I he hore is aeeepale, \iewaly inspeet all of the heed Tote and matin ap bolt holes fr pale or stripped thread everything checks out take the block to the machine ‘hop snd have ie “hot tanked” Hor tanking is a generic term tised to describe the eaastic ing fare and your block chowe Sia i eng cleaning process used by many ‘machine shops. Fallow the hot tonk cleaning with @ jetspray leaning process det seaning i f much faster process than most Hot tens and is eopeially use following the various block mi hining processes, Crack Inspection ‘Now tha the block has besa \horougily leaned, earful sual Inspeetion for evacks Ia mandatory. Cracks will most ‘often be found inthe ler valley, ‘slinders bores, between eylin ders, external water Jaekets and tain hesring webs. i not limit your checking to these areas Blane Use a strong shop light to inspect all areas of the entire os, Tf no eracks are apparent, take the block to the machine shop and have it Magaaflaxed Magar ie-s erack detection process whereby the entire Bloc. Emagnetized ond then sprin ‘eed with a magnetic powder, Since’ crack causes a dierap The Magali process begins by ‘agretang the noc usrg neat (Gage cio anata arr u ‘On the ook ha been cove wth fo rdcator 2 spec hier [ip sed fo nspect Bh or ‘ea suraurang ne ozo ng 2 ‘ack. Hore the tsoncan i hac ‘ram ca sooo tray rs of tion in the magnetic ila, the powder cllecte along the crack Hllowing the inspovior to easily feo If for any veacon the Nag af test in inconclusive, have the block pressure ested as a wasup Deburring "The purpose of deboring the block fo setuee tbe number of frags where eracke could start find tohelp redo the posibaity Gtreasting flash becoming ls Tedged aud ruining the engine, Proper deburring Fequires that all sharp edges be smoothed on both the inside and outside of the bloc This does not mean that every edge should be rx fused. It simply means that these edges should be given 2 mld chau, Dont overdo Be fre tn chan al i! eats in the back, Dont forget to deburr ing. a back, (ok for and wr mafestinade hobeck 9th ‘Tei poce wat rg che the oil ata holes i the can falters. Ths ta made easier by Ging lone. tapered dei to nock off any large picces of Slag hnwever jou must te ex frome care not to damage the Sock ‘Many people recommend polishing the iter wll to me rove ol draieck Ts nat ree Smmend. this. procedure oa Street performance snes fr tee seasons Fr, the ugeven {Sitare of te cart rom haa a recess aren tho See Titi paohe. Tis rug mur face helps improve heat Sia ‘Son, Seton She elt Smount of otha in pumped fo ihe tp ofthis pata engine Cosy toa rd sap epee texas poss of cack maton ones present mich of a prob; Seo rowed for noancce ot Seok ner 7 ery h repet te windage 00 ine ce. Te repent no don" belowe thie Tange aman ‘A att carte stout be ven 1 a sha ees ie he ck ‘Sret aciane mcus hese wes, ‘ema tay 4 cf work provides any significant ‘savantage Using a small “lex.type" brake evlinder hone, lightly hone each Tiler bore ta brea sy glaze that may be present fnd to condition the lifter bore for the installation of the new her, "The Final step in doburring involves ‘chasing all of the ‘heeded holes wath a tap. Using flight and a harp, carrot ‘zed hottoming tap, chase each threaded hole wing hand pres sive ony. Thread chasing is done to can the theeads of any fo ign material. Therefore, ab ‘ately no material shoul be re moved from any of the threads. ‘Once thief don, all of he holes ‘hou be chamfered sy an 82 Aegreechamferiag it. ‘Onc you have rocked wn a of fh stp sages sound the Bock in a propery sized Mow-rone The block eter des should aby fi aturng the or of Bo {ave mocame chanfotag poeas 2B be rar mar ti Sra eb nono edges You ilo nghan ine ra deburg proces troup each iter bore 0 smooth ¥ Machining the Block " ‘all machining operations stout be dane by a qualified ma ) e. thine shop, Hostever ee impor fant that you understand the purpose of each operation that ‘sil be performed on your block. Also, Twill make few recon: ‘mendations to holp guarantee {Bat youroney i wail sen Keep a notepad close at hand Ahroghout ths seston Align Honing "Eos al mor inder bask rnachining aperstione are i ened from the crankshaft bore entering, the Best thing that Se mae detains the cond Bo a the main bearing bares the main ae nt the proper meter and are not praperly Ste here ino posible rey foproduce an engine that is eB State tthe worn any Each and erey bot le meat be bated wit a ot cng ol sh CO toy tas fw show ‘od faloung mo dedrieg proce: = WES40 nyt ho apy hana, sas ofan inch of misaliga ‘ite Komentar see's Srp ap—evorna wrench ent fn the bearing centelines ra bearing bore that i lightly tof apeticatin to spell dias. tor. Therefore, before you spend (he dime on machine works so fost first measure each main Tearing bore and check ta ee that all of the mains are on a ‘oman entrine. Main bearing alignment is the first im that ent be vere fe"This mentor sno on tetablish without the une of ome Sather specialized (et simple Sauipment 0 tia procedure i E&Stion tothe machine shop. Es ently checlong msi bearing ligament requires the wee of esc gen wa gs A ‘arp ana banal @ Sn that is ound to ery close tle nics and hardened to maitain ‘rabalty ad accuracy The bor {s postoned inthe main bearing flo and i rocked back and forth slightly to ensure that iis CGrvectly tstlled: Once this i Sccomplished, feeler gages are Fotow up the theadchasng proce Gry lot chamtorng ach hows ‘used to determine if the bearings Dot ta using an 82 dope cha fre propery aligned. A good Bock feng, ‘illshow no mere Usan 000i of 16 devin seo al of the Bearing Sle yoo Blok en xcs Gf the tare, wil requ ‘machining to revtore the proper earng alee: fhe bearing ligament lly wth ise sp TGfstons, the next step 8 0 Check the bore det SMearurng the main baring toras ean be accomplished trang waya, To eases method Twwocaseletonpaapas sed ‘Reomeler However dl bore fear prebaly the bet to for {Shh Bact oe aba be mea sured on fis vere axl about sovao degrees fom the paring Tino Ina cases (20, 25,28, a 440 liter) the bearing bores Stole between 2 886i and se awa guge'o check aman gage ne bag sade yc 29874n in diameter besiege por sry machin. gfe guage acts oth "Align haring is & machining Soha te ter spre ne nop proce used feta the mah Wi te way gauge accurately can ‘eine bear sates te ea lng be alent cached us & arse bearing bore diameters to their Broper TD, nd to eorret aay fain bearing alignment errors. Instat, the alga honing proces involves removing small fount of material from the

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