Dismiss Notice



Register Today It's free! This box will disappear once registered!

4.0 OHV into 4.0 24v COSWORTH

Discussion in 'Need for Speed!' started by Tobbe, January 13, 2007.

  • Searches ExplorerForum.com
    1. Tobbe

      Tobbe New Member

      Joined:
      November 27, 2006
      Messages:
      30
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Sundsvall, Sweden
      As the topic. It's based upon a 93:ish 4.0 bottom end and the rest of the bits are from a 2.9i 24v BOB cosworth. Just missing a few bits to be able to put it all togehter. But here are a few old pics from how a few bits fit together.

      [​IMG]

      [​IMG]

      [​IMG]
       
    2. Support EF

      Join the Elite Explorers for $20

      Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself, and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.


      to hide adverts.
    3. 410Fortune

      410Fortune ELITE BRONCO2ERER Staff Member Moderator

      Joined:
      August 3, 2000
      Messages:
      22,220
      Likes Received:
      97
      Trophy Points:
      68
      City, State:
      7B Panhandle
      Year, Model & Trim Level:
      B2 Mod
      more details please :)

      Whats it going in? How much power did it end up making? Is the 4.0L block left stock?

      Looks bitchin
       
    4. CodePoet

      CodePoet Well-Known Member

      Joined:
      July 11, 2002
      Messages:
      2,426
      Likes Received:
      1
      Trophy Points:
      58
      City, State:
      Indianapolis, Indiana
      Year, Model & Trim Level:
      1993 XLT
      What he said! Got a dyno sheet? :D
       
    5. Tobbe

      Tobbe New Member

      Joined:
      November 27, 2006
      Messages:
      30
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Sundsvall, Sweden
      It's not finished yet. I would guess it will be around 300bhp with theese heads and stock cosworth parts, a 2.9 cosworth bored and stroked into 3.7 yields 278bhp and 407Nm with everything else stock. The bottom end is still stock but I am looking for other stuff for it, but I got a limited budges so I am open to suggestion to what to use in it. I am going to use the engine in a car known in Europe as Ford Sierra 2.9, looks just like the sierra cosworth. The engine management will be the low budget megasquirt and edis, but it will be mapped on a dyno so it will be done correct.

      The way of the oilpump rotation had to be fixet.
      The block needed a bit of welding so the chain guide would line up. Also the timing cover needed some work, and also a few guides did too.
      Custom headgaskets are on order, they are part of the solution to cover up the oil returnes in the V.
      And a few more bits have been done.
       
    6. Turdle

      Turdle I bake stuff Staff Member Moderator Elite Explorer

      Joined:
      June 16, 2003
      Messages:
      28,502
      Likes Received:
      547
      Trophy Points:
      143
      City, State:
      Humboldt, KS
      Year, Model & Trim Level:
      2000 Mounty
    7. Tobbe

      Tobbe New Member

      Joined:
      November 27, 2006
      Messages:
      30
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Sundsvall, Sweden
      I heard from some bloke that it should be possible to bore the block into 4.030 and use chevy 350 pistons and 6" rods, with some smaller mods. Any one know if this is possible? Also one thing to know is that the volume in the head is only 33cc. So it must be possible to machine down the piston crowns a bit.... Maybe there are some low compressions ones that will fit without any hazzle? I got no experience what so ever of chevy stuff. But I know that they are cheap.
       
    8. 410Fortune

      410Fortune ELITE BRONCO2ERER Staff Member Moderator

      Joined:
      August 3, 2000
      Messages:
      22,220
      Likes Received:
      97
      Trophy Points:
      68
      City, State:
      7B Panhandle
      Year, Model & Trim Level:
      B2 Mod
      yikes, I am sure its possible, but the OHV 4.0L is already a bored and stroked block the walls can get quite thin when they are bored.
      There are plenty of go fast goodies available for your V6 these days including engine internals. Because the SOHC 4.0L was used in the late model Mustangs the aftermarket for these engines has finally gotten a boost. Try a search on this forum to find the builders/4.0L V6 experts and shops that are out there.


      The 4.0L OHV bottom end is known for its durability.

      Have heard of people using a mix match of SOHC and OHV parts together to make some wild engines, one of them here in Colorado runs on race gas only because his SOHC pistons in a OHV block has like 15:1 compression.


      Did you convert the 4.0L oil pump drive using 2.9L parts?
       
    9. Tobbe

      Tobbe New Member

      Joined:
      November 27, 2006
      Messages:
      30
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Sundsvall, Sweden
      Did fail on machining a own helicalgear so the 2.9 stuff had to be modded with bigger journals, and also the distributor dummy plug is used, ofcourse there are some moddes to the lock washer aswell. Got a spare saft from a mate in UK, did also get a few other parts so I still can put the 2.9 together.

      [​IMG]

      The pistons I can sort out, but the connecting rods... By the way, is there any web shop where you can get stock piston rings for the 4.0 in US? Over here they cost more then 300$ for a set.

      This home made piston for the 2.9 is a close copy of the stock one but with a bit lower compression. Valve cuts out have been added, they were done in another machine so that's why the aren't present in the pictures. Maybe a nicer one should do for the 4.0.

      [​IMG]
      [​IMG]
       
    10. EMG7895

      EMG7895 Well-Known Member

      Joined:
      November 7, 2003
      Messages:
      1,700
      Likes Received:
      0
      Trophy Points:
      46
      Year, Model & Trim Level:
      '91 xlt, 93
      Nice work, I'm not familiar with the cossworth so I cant help very much. But I can tell you that you should be safe leaving the bottom end alone if you wanted. You have to try pretty hard to kill the bottom end in the 4.0, I have seen one with over 200,000 hard mile on it taken apart and it still was within spec.
       
    11. jah81592

      jah81592 Well-Known Member

      Joined:
      June 12, 2005
      Messages:
      1,473
      Likes Received:
      1
      Trophy Points:
      48
      City, State:
      Hueytown,Al
      Year, Model & Trim Level:
      1998 Explorer Sport
      Those heads look similar to the 32V 4.6L(ports,valvetrain).
       
    12. Fredness

      Fredness Elite Explorer

      Joined:
      June 2, 2000
      Messages:
      579
      Media:
      1
      Likes Received:
      9
      Trophy Points:
      18
      City, State:
      Tejas!
      Year, Model & Trim Level:
      '05 Sport Trac Adrenalin
      What are the chances of getting these heads/intake in the US?
       
    13. Minivek

      Minivek Active Member

      Joined:
      July 22, 2003
      Messages:
      443
      Likes Received:
      2
      Trophy Points:
      0
      City, State:
      Quebec, Canada
      Year, Model & Trim Level:
      '03 Limited Ex silver
      saw some heads on ebay just type cosworth head, but they're in england of course. Really interesting setup he's got there. Hope we'll see a finished product!!
       
    14. dkchrist

      dkchrist Well-Known Member

      Joined:
      August 13, 2006
      Messages:
      1,342
      Likes Received:
      0
      Trophy Points:
      46
      City, State:
      Fayetteville, AR
      Year, Model & Trim Level:
      93 XLT 4DR
      subscribing
       
    15. Stic-o

      Stic-o Elite Movie Star Elite Explorer

      Joined:
      September 1, 2002
      Messages:
      13,274
      Media:
      17
      Likes Received:
      216
      Trophy Points:
      93
      City, State:
      Lake View Terrace, CA
      Year, Model & Trim Level:
      '91 Navajo '99 XL '16 XLT
      Very Nice:thumbsup: My dad has a '69 Cortina GT MKII we've talked about putting a 2.8 or 4.0 into.;) This would be pretty cool in it too though:D
       
    16. Heavymentill

      Heavymentill Active Member

      Joined:
      March 8, 2004
      Messages:
      588
      Likes Received:
      0
      Trophy Points:
      16
      City, State:
      Ann Arbor, Michigan
      Year, Model & Trim Level:
      96 Explorer Limited
    17. Tobbe

      Tobbe New Member

      Joined:
      November 27, 2006
      Messages:
      30
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Sundsvall, Sweden
      Wonder how it turned out for him, if he ever finished the engine.

      There's a big differ between his and mine engine, his was BOA based and my is BOB based, meaning different heads, chaindrive and inlet. The only boa stuff I am going to try to use is the thermostat housing, if possible.

      Besides the 2.9 BOB gives 207 bhp and the BOA 195bhp, so for 2 reasons it is better to go with the BOB, 1# more power 2# it is easier.

      And an other big differ is that I got a 2year old CNC lathe with driven tools, cad cam, bet he does not:D
       
    18. jah81592

      jah81592 Well-Known Member

      Joined:
      June 12, 2005
      Messages:
      1,473
      Likes Received:
      1
      Trophy Points:
      48
      City, State:
      Hueytown,Al
      Year, Model & Trim Level:
      1998 Explorer Sport
      That would be cool! I was super excited till I got my head out of my rear and realized that they wouldn't work with the SOHC.Darnit!
       
    19. Fredness

      Fredness Elite Explorer

      Joined:
      June 2, 2000
      Messages:
      579
      Media:
      1
      Likes Received:
      9
      Trophy Points:
      18
      City, State:
      Tejas!
      Year, Model & Trim Level:
      '05 Sport Trac Adrenalin
      Well, I'm not up on SOHC/OHV block differences, but why wouldn't it work?

      It's my understanding that the SOHC oil pan bolts to the OHV, so worst case you use an OHV block, SOHC oil pan/girdle and the Cossie DOHC heads and intake, right? Or are you talking about the chain difference where the Cossie uses two long chains and we use 3 shorter chains off the "Jack Shaft"? I think that actually works to our adavantage! We could modify the internals to use the Cossie 2 chain system and not have to fab/modify our timing cover... maybe...

      Other than not being able to do the DOHC head swap in an afternoon with the 4.0L SOHC engine still in the mounts of your Explorer, What's wrong with that? :D

      I think I'm missing something on the oil pump drive though. The cam has an opposite direction drive for the oil pump, OK, I got that. So what? Is there a reason the lobes can't be ground off the 4.0L OHV cam and use the 4.0L OHV factory oil pump/drive? I think the issue here is :uk: vs. :usa:, with Tobbe's inability to access to :usa: parts.

      Tobbe: What timing cover are you using and does it bolt up? There looks to be a CnC (2mm?) adapter beween the timing cover and the heads, can you confirm/elaborate? What oil pump are you using (Cossie, I assume) and why? Thanks!
       
      Last edited: January 19, 2007
    20. Tobbe

      Tobbe New Member

      Joined:
      November 27, 2006
      Messages:
      30
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Sundsvall, Sweden
      Actually, I have heard of a SOCH based engine being built in Norway, it uses 2lhs heads. More I don't know, got this info from a mate in UK. And there is also a guy in Belgium that have plans on a OHV based one, but I haven't heard any more from him. I tried to offer him some help but......

      Have a rethink of the oil pump drive. With the 24v chain drive the 4.0 camshaft will rotate the opposite way that it would with the 4.0 chain drive. Meaning the oilpump would rotate the wrong way. This must be sorted, and the easy way to do it is to use the cosworth jack shaft, still the cosworth gear doesn't look to good on the 4.0 cam so you got a problem there aswell, it's not even close to line up to the rest of the chain drive.
      I still have the 4.0 pump in the bottom end, and I didn't really plan on changing it for the cosworth one either.

      I am using the timing cover from the cosworth and it lines up pretty good. Yep there are spacers. The 4.0 block is 20.1-20.2 mm higher then the 2.9. The gap you see will have a gasket later on, and in the pictures the heads are a bit higher then they will be later on when the real head gasket is assembled.
       
    21. Fredness

      Fredness Elite Explorer

      Joined:
      June 2, 2000
      Messages:
      579
      Media:
      1
      Likes Received:
      9
      Trophy Points:
      18
      City, State:
      Tejas!
      Year, Model & Trim Level:
      '05 Sport Trac Adrenalin
      Now it make perfect sense, I should have figured that from the "missing chain". I think, If I were to be able to get the heads, I'd go with the SOHC style and the 3 short chains.

      Man, That is some great work! Thanks for the reply...
       
    22. Tobbe

      Tobbe New Member

      Joined:
      November 27, 2006
      Messages:
      30
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Sundsvall, Sweden
      Hmm, did find a really cheap SOCH, maybe I'll pick that one up and have a closer look at it...... Besides, it's 207bhp enigne, maybe it just need some breathing help, 2xTT conversion might help it a bit.... It's getting to many projects in the garage soon,
      4.0 cosworth N/A
      2.9 TT cosworth
      3.5 BMW N/A
      2.0 Pinto turbo with dual spark.
       
    23. Minivek

      Minivek Active Member

      Joined:
      July 22, 2003
      Messages:
      443
      Likes Received:
      2
      Trophy Points:
      0
      City, State:
      Quebec, Canada
      Year, Model & Trim Level:
      '03 Limited Ex silver
      How are things coming along???
       
    24. Tobbe

      Tobbe New Member

      Joined:
      November 27, 2006
      Messages:
      30
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Sundsvall, Sweden
      Buying the car for the engine on saturday if everything goes as planned, it only weights 1210kg, so 0-60mph should be wrooooom. The head gaskets have been cut, still waiting for the copper for the firerings. Did never buy that SOCH, I got enough to do anyway. Got a slide inlet under construction, I have also bought a set of bigger injectors. Getting the pipes for the headers and exhaust next week. 42mm inside diameter, 60cm long, baffle collector, 2.5" from collector to where the sides meet up and then a 3" single pipe to the rear. Still need to find 6 air filters of correct size. Also thought of buying other springs and shockers for the car and also poly bushes all around. But maybe I should wait with this until I got the car rolling with the engine. I'll make some updates when I got some new pictures....
       
    25. Jakee

      Jakee Well-Known Member

      Joined:
      May 6, 2006
      Messages:
      2,826
      Likes Received:
      1
      Trophy Points:
      0
      City, State:
      Huntsville, Texas
      Year, Model & Trim Level:
      01 Sport
      Talks about a engine rebuild. Man, I'd be scared to death starting that thing up for the first time. Might end up smashing an atom or something.
       
    26. Tobbe

      Tobbe New Member

      Joined:
      November 27, 2006
      Messages:
      30
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Sundsvall, Sweden
      No worries... It will run nice without any problems:D I hope..... I just hope that the bottom end is up to the job. The parts in it is not as strong as the 2.9 cosworth bits.... Time will tell...
       

    Share This Page







    We Support Our Troops!