1988 ('06) E350 Van Build
- Thread starter Built By Fluffy
- Start date
Previous video I got of the engine running, after doing multiple purges of bubbles in the fuel lines (and the aforementioned exhaust leak)
She's still cyclical in her idle but not nearly as rough, and the sucking sound I had earlier is gone. I'll be less rash to anger (even if the company in question screwed me previously) so here's hoping that head gasket is fine.
I've since taken the pump off and redid the timing. After purging again I'll give her another try, but in the meantime I'll be working on the throttle linkage and disassembling the 1988 van
She's still cyclical in her idle but not nearly as rough, and the sucking sound I had earlier is gone. I'll be less rash to anger (even if the company in question screwed me previously) so here's hoping that head gasket is fine.
I've since taken the pump off and redid the timing. After purging again I'll give her another try, but in the meantime I'll be working on the throttle linkage and disassembling the 1988 van
Tons of Updates!
First off, the throttle linkage is done. This was a little tricky since the throttle for the om606 come underneath the air intake plenum with a 3.5" throw, while the van's throttle cable went to the right top of the engine with only a 1.5" throw. I made a linkage that bolts to the top of the om606 and comes through the back
I also punched out the parts I needed to build a new front winch bumper while I was working on the throttle, but that will be a later post. The other bigger update is the body swap is done! Dad came into town and we knocked it out in about two days of work.
It'll still be a little while till she's up and running, but that's a major step done. Up next is connecting all the fuel, coolant & oil lines, replacing the steering column, rewiring the van and getting the intercooler set up. All that should get her drivable so the rest is just cleaning/redoing the interior and just buttoning up things here and there. Very excited with the progress
First off, the throttle linkage is done. This was a little tricky since the throttle for the om606 come underneath the air intake plenum with a 3.5" throw, while the van's throttle cable went to the right top of the engine with only a 1.5" throw. I made a linkage that bolts to the top of the om606 and comes through the back
I also punched out the parts I needed to build a new front winch bumper while I was working on the throttle, but that will be a later post. The other bigger update is the body swap is done! Dad came into town and we knocked it out in about two days of work.
It'll still be a little while till she's up and running, but that's a major step done. Up next is connecting all the fuel, coolant & oil lines, replacing the steering column, rewiring the van and getting the intercooler set up. All that should get her drivable so the rest is just cleaning/redoing the interior and just buttoning up things here and there. Very excited with the progress
So I haven't posted in a while, mainly due to frustration but also because I promised my wife I'd give the project a break for a bit while we move.
Long story short, the engine I got from Montoyas was bad and putting performance parts on it made it go from bad to Boom...
I haven't pulled the head yet to really diagnose what went wrong but I did get a borescope up to the open valve in cylinder 6 (the one with no compression) and the crosshatch looked fine. If I had to guess I either bent a rod (unlikely) or a valve, a messed up valve or valve stem would explain the excessive smoke I was seeing for the short period I did have the van running. She no longer turns completely free, at a certain point it takes about 90 ft-lbs to turn over which didn't happen prior to the smoke and poof, so I definitely made something worse.
That said, while it was running, it did have great power once the turbo kicked in but the low end was lacking to the point to where I can no longer start the van in 2nd gear. The ZF-5 has a 5.72 1st gear and a 2.94 2nd, which makes it kinda like a 4 speed with a granny low, but I now need that low. That won't be good for heavy traffic or offroad situations so, I figure I have 3 options:
1) rebuild the engine as an om606 stroker using a crank from a a 350sdl (should end up at about 3.3L) and have a custom heavier flywheel made.
I'm leaning towards options 1 or 2 at the moment. I'd like the experience of rebuilding an engine but the 6bt would also be a great setup. The other dumb idea I had for fixing the torque/drivability of the om606 would be to custom build the bell and torque converter from a 722.6 into a doubler fitted in between the engine and ZF5. Tons of custom machining work in that but the 722.6 does house the oil pump and cooler lines in the bellousing specifically, adding it in-between would give me the benefits of the of an auto and a manual, and it'd be easier in traffic.
Think the old VW autosticks, that's where I got the idea.
Long story short, the engine I got from Montoyas was bad and putting performance parts on it made it go from bad to Boom...
I haven't pulled the head yet to really diagnose what went wrong but I did get a borescope up to the open valve in cylinder 6 (the one with no compression) and the crosshatch looked fine. If I had to guess I either bent a rod (unlikely) or a valve, a messed up valve or valve stem would explain the excessive smoke I was seeing for the short period I did have the van running. She no longer turns completely free, at a certain point it takes about 90 ft-lbs to turn over which didn't happen prior to the smoke and poof, so I definitely made something worse.
That said, while it was running, it did have great power once the turbo kicked in but the low end was lacking to the point to where I can no longer start the van in 2nd gear. The ZF-5 has a 5.72 1st gear and a 2.94 2nd, which makes it kinda like a 4 speed with a granny low, but I now need that low. That won't be good for heavy traffic or offroad situations so, I figure I have 3 options:
1) rebuild the engine as an om606 stroker using a crank from a a 350sdl (should end up at about 3.3L) and have a custom heavier flywheel made.
the good: That should fix my odd clutch issue as I can have the flywheel made to accept the right ford parts. The longer stroke and heavier flywheel should also help tremendously with low end torque.
the bad: It will take me quite a bit longer to get this van on the road, which I'm already a year delayed on this project. It'll also be my first for an engine rebuild
2) Change gears completely and swap in a Cummins 6btthe good: parts are everywhere in the us, everyone and their dog makes aftermarket parts, its been done before, gobs of low end torque, the NV4500 I'd probably swap in at the same time is stouter and has a lower 1st gear that the ZF5, and it would allow the van to tow which opens up our camping options.
the bad: while I can get the engine, trans and tcase package easy enough it costs more than rebuilding the om606 myself (cheaper than paying someone to though). I'll end up with a junked om606 and a bunch of performance parts I can't use. As I found out researching, its actually more expensive to mod a 6bt than an om606 (desirable engine I guess). And the MPGs wouldn't be as high as I was aiming for, one of the main reasons for the swap in the first place.
3) Buy another used or rebuilt om606 enginethe good: my van is already set up for it so it'd be quick and we'd get her back on the road in time for an offroad event I wanted to attend. I'd also end up with and engine's worth of spare parts
the bad: it doesn't solve my torque issues, for a used engine (even though from a more reputable source) still might be bunk and will cost me as much as the rebuild parts, a professionally rebuilt engine would have the reliability but is by far the most expensive option.
I'm leaning towards options 1 or 2 at the moment. I'd like the experience of rebuilding an engine but the 6bt would also be a great setup. The other dumb idea I had for fixing the torque/drivability of the om606 would be to custom build the bell and torque converter from a 722.6 into a doubler fitted in between the engine and ZF5. Tons of custom machining work in that but the 722.6 does house the oil pump and cooler lines in the bellousing specifically, adding it in-between would give me the benefits of the of an auto and a manual, and it'd be easier in traffic.
Think the old VW autosticks, that's where I got the idea.
