-I have not been able to find a crate or rebuilt engine to my liking and specifications, So I started collecting parts to build my own Forged 4.0L Engine.
-The Cylinder Head is the limiting piece of a 4.0L engine build. It is a non-cross flow design and has very poor flow and performance. Some years '00-'02, 0331 heads, are even prone to cracking.
-I like the concept of the New Edelbrock Alumn head, but at this point with NO track record, I am going to pass and use the Proven cast iron jeep head on this I6 engine
-The pin and spring method or even the fitted pin or bolt method of controlling cam walk is marginal at best. I want '99+ block with the cam retainer plate.
-The stock head flows so poorly for 4.0L and is even worse for a 4.6L stroker. Even with simple polishing and pocket porting. Porting without flow bench support/comparison is just plain stupid.
-Stock Valves- Intake = 1.91"(110grams), Exhaust = 1.50"(88grams)
PARTS
-Head- new aftermarket casting, thicker and stronger
-Valves- Mopar Stainless steel, 2.02" intake (116grams) and 1.62" exhaust (90 grams), single groove for locks, they will be slightly shrouded but the 0.060" over bore will help to un-shroud the valves, these bigger valves will still outflow smaller 'un-shrouded' valves
-Springs- Lunati (49 grams) Ovate Beehive, at 1.64" install height- 100psi seat, 235psi at 0.500" lift (stock 71 grams)
-Retainers- Mopar hemi, (9 grams), lighter than titanium SBC retainers, (stock 16 grams)
-Locks- Mopar hemi, (3 grams), single groove
-Victor Reinz gasket set, MLS head gasket 0.043"
-ARP- head studs, rod bolts, main cap bolts, flex plate bolts
-Block- seasoned '99 block with the cam retainer plate
-Pistons- RaceTec forged custom made 1.625" pin height for 0.000" deck, 14cc dish 3.935" 9.2:1SCR 7.94:1DCR
-Piston Pins- 0.931" x 2.688" 0.136 wall 119 gm
-Rods- Scat forged 6.125" with ARP bolts good to 550+HP 756 gm
-Crank- stock 4.0L 3.411" stroke (next engine will get 232 3.50" stroke crank and Eagle 6.150" rods)
-Cam- for boost, Jones Cams 204/216 0.502"/0.519" with 1.7 rockers 113 LSA on '99+ core
-Cam- Built N/A 4.0, Jones Cams 204/208 0.472"/0.478" with 1.6 rockers 113 LSA on '99+ core
-Timing Chain and Sprockets- Cloyes C3225 , maybe double roller chain in future (yet to be made)
-Rocker Arms- Roller Rockers 1.7:1 Harland Sharp Custom made
-Lifters- Johnson- Hylift hydraulic flat tappet
-Push Rods- 5/16", Trend or Smith Brothers, 5/16" 0.080" 210* double ball end
-Oil Pump- Melling M81A standard 4.0L
-Fuel Pump- Walbro 255LPH (S/C), 190LPH (N/A)
PLAN
-3.935" bore and stock 3.411" stroke, 3956cc to 4078cc +122cc = +3% more power
-0.000" deck clearance, 0.043" Quench
-9.0-9.2:1 CR, +0.5:1 = +1.5% more power
-port head
-stock ECU, 703/784 injectors
-braze oil pump pickup to oil pump
-check top rod balancing pad to under piston crown clearance
-cam retainer plate 0.004" movement
EXPECTATIONS
-bore +3%, CR +1.5%, head +8%, cam +8%, Quench +3%, headers/etc +8% TOTAL= +31.5%
-stock 190HP/225TQ + 31.5% => 250HP/300TQ
-N/A expect 240-250 crank HP, 280-300 crank TQ
-Supercharged 8 pounds boost +50% = 400 crank HP / 450 crank TQ
-Mustang Dyno 2WD AW4 300rwHP/350rwTQ
VALVE SPRING REPLACEMENT
-Mopar Performance Springs #5249464 are no longer produced or available, were about $150/12 pcs.
-MP Springs Specs- 270-284 lbs/in installs at 1.64" safe to 0.525" lift 1.418"OD
-115-118 lbs@1.64" 255lbs@1.190"(0.450"lift) 272lbs@1.140"(0.500"lift)
-need to find suitable replacement with similar or less spring rates
OVATE BEEHIVE VALVE SPRINGS
-Time to Upgrade and use NEW valve spring technology
-In any spring, the inner diameter experiences significantly more stress than the outside.
-The ovate multi-arch wire design of these revolutionary valve springs places more material on the inner diameter of the spring, which more evenly distributes stress throughout the wire cross-section and increases the overall life of the spring.
-Other features of the Ovate Beehive Valve Springs include reduced mass in the retainer end of the spring, which increases RPM potential, and reduced coil surging for more valve control and longevity.
-Lastly, a thinner cross-section wire gives more coil bind clearance to allow for camshafts with higher lift or higher ratio rocker arms.
-The Ovate Beehive Valve Springs are the ultimate in cutting-edge valve train performance.
specifications-
-0.600" lift Beehive Valve Spring Spring Rate: 275 lbs/in Coil Bind: 1.040"(0.600"lift)
-Big End OD/ID- 1.061"/0.698" Small End OD/ID- 0.999"/0.636"
-Seat Load 100 lbs at 1.640" Install height 1.64"
-224 lbs at 1.190"(0.450"lift) 237 lbs at 1.140"(0.500"lift)
-spring weight= 49 grams, retainer weight= 9 grams LIGHT!! (vs. stock 71 grams and 16 grams)
-Nearly identical to MP specs and excellent choice for replacing or upgrading stock valve springs
DON'T WANT- (from JeepStrokers.com, 4.6L stroker build-CLICK HERE)
What is the definition of INSANITY? Doing the same thing over and over and expecting a different result!
Initially 2 Titan stroker engines failed, then
Rebuilt a different block-ReInstalled, Initial time #1
1)Thrust bearing blew/wore out, Mopar Perf springs 110# seat, 250# open, Engine Removed-Rebuilt-ReInstalled #2
2) Comp Cam died, nose of lobe flattened/wore off, Engine Removed-Rebuilt-ReInstalled #3
3) Comp Cam replaced with Isky, oil pump and pickup replaced, Lunati lifters, Joe Gibbs oil
4) Failed Clevite bearings #1, Engine Removed-Rebuilt-ReInstalled #4
5) Thought the cam not being straight was the cause
6) Isky sent another cam, engine cleaned, new bearings all around, Johnson lifters, Brad Penn oil
7) Durabond bearing set fails after ~100 miles, oil pressure dropping, Engine Removed-Rebuilt-ReInstalled #5
8) Found lose oil pickup on pump
9) Different block 99+, Hesco RVOB, KB944 0.040", Durabond cam bearings, Clevite main and rod, cleaned engine, Hesco lifters, Brad Penn oil
10) Durabond bearing set fails after ~100 miles, oil pressure dropping, Engine Removed-Rebuilt-ReInstalled #6
11) Find spot where oil pump is being held off block, not flat mounting, clean up oil drain back holes, 'restrictor' pushrods, HV pump and new pickup, Johnson lifters, Sealed Power bearing, Brad Penn oil
12) Bearings die again, this time with much less wear on double miles. Oil pressure was steady at 40psi hot idle, Engine Removed-Rebuilt-ReInstalled #7
13) use 'coated' bearings', tighten pin/spring and cam walk, (had 0.105" movement) finally lasts
14) Update- Finally re-uses the cam retainer plate, WHICH ORIGINALLY CAME WITH THE ENGINE!! and a Jones cam 99+ with 1/2" lobes, No failure, AFTER 7 TRIES!
UPDATES
-Head done
-all parts bought
-used '99 extra long block stripped down to bare block
-long block taken to machinist for machining and assembly
Head Flow Numbers- 0.100 0.200 0.300 0.400 0.500" (RED highest value)
7120 0630 Head stock 66.0 128.0 179.0 206.0 219.0 Exhaust- 55.0 100.0 120.0 136.0 141.0
HO head 0331 Intake- 59.4 122.6 171.1 201.1 214.3 Exhaust- 47.1 093.4 123.3 140.9 147.0
Ported HO head 7120 68.4 132.6 185.4 213.4 216.5 Exhaust- 64.3 116.9 149.6 158.9 165.0
Ported HO head 0331 65.2 128.4 186.5 219.5 218.9 Exhaust- 56.9 096.9 123.9 140.2 148.9
Ported HO 2.02/1.60 73.9 142.4 197.8 229.8 247.0 Exhaust- 65.3 114.0 135.9 146.3 157.1
Dr.J ported 1.91/1.50 67.0 137.0 190.0 227.0 237.0 Exhaust- 60.0 101.0 133.0 164.0 182.0
Hesco head 1.91/1.50 74.0 134.0 183.0 226.0 255.0 Exhaust- 55.0 093.0 117.0 131.0 142.0
Hesco Port 2.02/1.57 61.2 116.8 164.7 205.3 235.2 Exhaust- 51.0 080.5 110.2 132.8 149.1
HO ported BV chamb 57.9 122.0 176.8 214.5 225.5 Exhaust- 49.7 091.8 127.0 153.9 165.5
Other 1.94/1.50 Chevy 177.0 214.0 Exhaust- 130.0 146.0
Ported 1.94/1.50 Chevy 185.0 216.0 Exhaust- 150.0 165.0
Edelbrock Alumn 4.0 Head 1.91"/1.50" 55cc 144ccIntake/77ccExhast (stock 112cc/73cc)
Edelbrock Alumn stock 66.0 123 179.0 221.0 241.0 Exhaust- 63.0 103.0 127.0 144.0 151
A'mkt ported 2.02/1.62 78 152 212 245 265 Exhaust- 66 121 159 172 188
Russ Pottenger Edelbrock Aluminum Head Flow Data 28" water
Edel stock 1.91"/1.50" 58.1 132 187.5 225 246 Exhaust- 61.2 104.3 123.9 152.2 156.9
Edel port BV1.97/1.55 72.5 144 199.5 246 274.8 Exhaust- 62.1 117.5 168.0 191.8 204.5
