It's been a few months since project Shake 'N' Bake has graced the pages of MM&FF. With over 90,000 miles on the clock, mechanical failures will happen. In our case, a failure in the oiling system led to our engine locking up.
The good news is there aren't any holes in the block, and even though we haven't disassembled it yet, we think the seized engine is repairable. (As soon as we know the extent of the damage, some sort of Four-Valve engine build will be in the works). As for our Mach 1, which until this point served as daily transportation, it's time to upgrade with Ford Racing's Aluminator crate engine, and we'll top it off with a ported intake test.
Chris Jones and Matt Frith...
Chris Jones and Matt Frith started the engine swap by removing the hood so the engine could be taken out. You can also drop the K-member and remove the engine from the bottom, but Jones and Frith had no problem pulling it from the topside.
Our new powerplant has to stand up to drag racing, high-rpm road-course days, and our daily back-and-forth commute. Given our performance needs, the Aluminator crate engine from Ford Racing Performance Parts (FRPP) is a perfect fit.
The 4.6 Aluminator is offered in a few different versions, and the first choice is between the short-block and long-block. Either way, the rotating assembly is comprised of a slew of forged goodies designed to support higher horsepower levels. The forged-steel Cobra crankshaft uses forged H-beam rods to move the coated, forged pistons in the stock-sized (3.552-inches) bores. The long-block and short-block both check in at the stock displacement of 4.6 liters (281 ci).
The next option is compression ratio. You have two choices in this department: 10:1 or a boost-friendly 8.5:1. Being that we have no intention of putting boost into the new engine, we opted for the higher 10:1, which is close to the stock Mach 1 mill that was 10.1:1 from the factory.
After removing all of the...
After removing all of the wiring harnesses from the top of the engine, along with the shaker, cold-air intake, upper intake plenum, and other accessories, Frith removes the intake manifold.
We could have used the heads off the old engine and possibly had some port work done, but to save time, we opted for the long-block configuration, which uses stock '03-04 Cobra heads and camshafts. When the crate arrived, we unboxed a near-complete engine with an oil pan and valve covers on it-it even had oil in it! All that was left to do was bolt on the old intake manifold and front accessories-but that just wouldn't be our style. Instead, we headed to Blow-By Racing (BBR) in Boca Raton, Florida to tackle the task of bringing Shake 'N' Bake back to life.
With the Four-Valve crammed in the SN-95's already-tight engine bay, most performance work requires pulling the engine. Being that our new engine was sitting on an engine stand, we figured why not make it better before dropping it in? A call to Comp Cams netted us four bumpsticks to help make the new Aluminator breathe easier.
Jones and Frith made quick...
Jones and Frith made quick work of removing the broken engine.
The stock sticks check in at 0.394-inch lift (10mm) with 186/194-degrees of duration at 0.050-inch lift respectively. Our new cams from Comp open the intake valves to a taller 0.475 inches, while the exhaust valves open to 0.450 inches off the seats. The duration is 234 degrees at 0.050 on the intake side and 232 degrees at 0.050 for the exhaust cams. Given the higher lift numbers, Comp recommends changing valvesprings when you do this cam swap.
After removing the timing cover, the timing chains and guides were removed before unbolting the cam caps. NMRA Hot Street racer Tim Eichhorn of Mustang Performance Racing in Boynton Beach, Florida, came by to give us a hand. Eichhorn's expertise with Four-Valve engines was apparent as he made quick work of the timing chains and showed us some tricks to swapping the valvesprings.
Comp Cams sent us a set of...
Comp Cams sent us a set of its Xtreme XE-R camshafts for the Four-Valve 4.6L engines. These shafts check in at 0.475-inch lift on the intake side and 0.450-inch lift for the exhaust valves. Duration is 234/232 at 0.050 respectively.
With the Ford tool for compressing the valvespring in hand, Matt Frith of BBR dove into our new engine, pressurizing each cylinder before compressing the valvespring and removing the locks and retainers. The process is then done in reverse to install the new springs.
The new Comp Cams valvesprings (PN 26123) are a 324-lb/in beehive spring, which gave us 90 pounds of pressure on the seat. Comp also sent new retainers (PN 799-32) to run with the springs. Once the springs were changed, Eichhorn used Royal Purple's Max Tuff synthetic assembly lube on the bearing surfaces and the cams before bolting everything back together. After Eichhorn and Frith buttoned up the cams, the timing chains, guides, and slack adjusters were reinstalled.
What's better than taking...
What's better than taking a brand-new engine and making it better? Frith has no problem diving into our new Aluminator engine.
NMRA Hot Street racer and...
NMRA Hot Street racer and engine builder Tim Eichhorn of Mustang Performance Racing came by to help with the cam swap. Eichhorn started by marking the cam caps so everything could be put back in the correct location.
Eichhorn and Frith then tackled...
Eichhorn and Frith then tackled the task of changing all 32 valvesprings. The stock springs were removed in favor of heavier springs from Comp to support the higher lift of the new cams.
Once the springs were replaced,...
Once the springs were replaced, Eichhorn installed the new bumpsticks with plenty of Max Tuff assembly lube from Royal Purple.
The cam caps are reinstalled...
The cam caps are reinstalled next and torqued down to 89 in-lb.
With the top of the engine...
With the top of the engine reassembled, Frith installed the new 8-quart oil pan from Moroso.....