1993 6.9 IDI Compound Turbo ZF5 Manual Bricknose Bronco Build

[Ace Perkes]

Hello! I wanted to share my project, this is my first time posting in a forum. I have quite the project in the making and though I would share.

I have a 1993 Ford Bronco XLT Lariat w/factory 5.8L I purchased a year ago @ $500 w/ the title. I knew from the beginning that there was no way I wanted to invest in a 5.8L that gets horrible MPG's. I had gone back and forth on what engine I wanted to utilize in my rig build.

Then comes the 1986 6.9L IDI @ 87,000 mi.I know this seems low, but I am convinced that it truly is 87k for a few reasons (pictures below). First, the seat is in immaculate condition, and as most know when they rip on the drivers side 90% of the time the odometer has in fact rolled over. Second, the pedals show very little sign of wear. Third, The battery terminals/positive rubber shields look practically new. Fourth, there is almost no sludge on the engine, I can see the block with ease which is typically caked on (compared to my father in law's 6.9). I bought this vehicle not running. Got her home, hooked a strap the front bumper, pull started her with my good ole 1996 EFI 4.9l F150. She fired right up within 15" of pulling.

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Picked up the motor for $300

I knew there was no way I wanted a 4 speed transmission, so I sourced a local good ZF5 transmission. Picked this up for $300.

This truck will also be running on 90-100% waste motor oil, processed through a centrifuge (no expensive filters for debris removal). With use of WMO I will mount 2 CAT filters on the frame rail to ensure that the motor oil is free of debris, down to 1 micron.

 

[Ace Perkes]

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Bronco teardown.

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[Ace Perkes]

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[Ace Perkes]

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[Ace Perkes]

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[Ace Perkes]

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[Ace Perkes]

A few videos of the donor truck.

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[SuperDave]

A donor truck is the way to go, when I decided to do a diesel bronco I bought a non running 88 lariat... Actually I bought $ 500 dollars worth of new bronco parts and got a free non running bronco with them. Then later after looking at several overpriced 6.9/7.3 engines (like $1200-$1500) I bought a whole running 87 f350 4x4 for another $600 and robbed it of everything that was different between the gas and diesel. I have to say it was a lot less difficult than I had imagined and with having the donor truck my bronco looks like that 6.9 came in it factory. Good luck with the build!

 

[IDIBRONCO]

I have to say it was a lot less difficult than I had imagined and with having the donor truck my bronco looks like that 6.9 came in it factory. Good luck with the build!

I'll have to second this.
Since you mentioned compound turbos in the title, how much boost are you planning to make? A 6.9 can't handle as much boost as a 7.3 can.

 

[Ace Perkes]

I'll have to second this.
Since you mentioned compound turbos in the title, how much boost are you planning to make? A 6.9 can't handle as much boost as a 7.3 can.

Before I put the motor in the Bronco I will install ARP head bolts and Mahle head gasket/valve cover gaskets. And for the winter I will leave it naturally aspirated. Come winter I will have the inter cooler and piping, waste gate, dual stage boost controller, along with all the gauges. I think I will keep the brick nose instrument cluster. I’ll put led’s in the cluster like I did my f150.

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It looks better in person. Pretty even color throughout.

The first turbo with air coming from the atmosphere is a Gm-3, internally controlled waste gate @150k. The secondary turbo is a Gm-4, externally controlled waste-gate (2 Stage controller, for daily/or/“race-tow” option) @ 45k. Both were given to me by my father in law.

 

[Ace Perkes]

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Here is a few pictures of the centrifuge setup.

Pabipdieselsupply.com

centrifugefordummies.com

I have a steel barrel, pump, fittings, & pipe ready to go. Just need the centrifuge & heater. I have access to as much oil as I can burn.

 

[Ace Perkes]

All of this is is just so I don’t have to pop the hood in a pinch but it was a big moment for me.

I also want to put a WD-40 solution in a bottle like this.

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Then I will need a good pump that can withstand prolonged WD-40 contact.

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rigged up to the little orange cap on the intake with some kind of sprayer. Just in case she decided to be stubborn.

 

[Ace Perkes]

For the winter, injection pump turned up, this is basically what maybe 1 weekend will consist of. With a lot more mudding than snow play.

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[IDIBRONCO]

I'm glad to see that you're planning to install head studs. They will help, for sure. I believe that the general rule of thumb is about 15 PSI max boost for a studded 6.9. You could possibly run up to 20 PSI, but I won't guarantee that. The 6.9's 7/16" head bolts/studs don't hold as well as the 7.3's 1/2" ones do. When you run too much boost for too long, you'll usually end up lifting a head and then there goes your head gasket.

 

[lotzagoodstuff]

I'm glad to see that you're planning to install head studs. They will help, for sure. I believe that the general rule of thumb is about 15 PSI max boost for a studded 6.9. You could possibly run up to 20 PSI, but I won't guarantee that. The 6.9's 7/16" head bolts/studs don't hold as well as the 7.3's 1/2" ones do. When you run too much boost for too long, you'll usually end up lifting a head and then there goes your head gasket.

This is solid advice. If you are really planning on compound turbos and high boost, and you are going to go through your 6.9, you should have the machine work done to the block to accept the larger studs that the 7.3 came with.