Not worth it IMHO......Especially in a heavy car. Especially in one with an AOD -- Not with stock heads.....
The differences between the non-HO and HO motors go deeper than the pistons and cam.....
The standard output (non-HO) passenger car fuel injected 5.0 was installed in the following cars:
1986-1988 Thunderbird/Cougar
1986-1991 Crown Vic/Grand Marq/Town Car/Continental
1986 Mark VII (non LSC versions)
These engines had the following:
--E6 casting heads with 68 cc chambers and smaller valves than their E7 counterparts.
--A MUCH smaller cam designed for low end grunt/low RPM cruising. This cam has the old school 302 firing order. 1-5-4 ......
--Pistons with a 2.5 cc dish and no valve relief (the overwhelming majority are cast -- there are reports of the very early style of this piston coming forged. They were available forged through aftermarket. HO pistons have the same dish AND valve reliefs that add up to another 4 cc for a total of -6.5 cc as opposed to -2.5...... The non-HO pistons also use different rings.
--Different upper intake manifold & throttle body. Stock HO manifold has a 60 mm opening for 87-93 (58mm in 86) as opposed to the 50 mm opening on the non-HO cars. Lower intake is the same. More evidence that on a stock HO motor the lower intake is the bottleneck.....
--14 pound injectors. Yes 14. It's been proven that 8 of these injectors WILL support just a hair over 200 HP on an N/A motor, but they're pushed to the max.....
**The base 5.0 cars came with smaller fuel pumps as well as different ECU's tailored for their smaller injectors/cam.
**The rods and crank are
identical between the non-HO and HO cars.
**All the non-HO 5.0 passenger cars were speed density EXCEPT the CV/GM/TC in model year 1991 only. These are the only cars with a base model passenger car 5.0 AND mass Air
**Every Mark Vii ever made with a fuel injected 5.0 left the factory with speed density -- both HO and non-HO
The Mark VII was HO in all 87-92 models. Prior to 87 they came with the base motor with the HO as an option. It was part of the LSC package. The only years for the 5.0 HO in Cougars and T-birds were '91-'93. No V8 in either in 89-90 (still hadn't designed that low rise intake minifold yet -- the optional motor was the supercharged 3.8)and all prior years were base model 5.0s. Interestingly enough the 93 Cougar and t-bird 5.0 has the same cam as a '93 Cobra, but with stamped 1.6 rocker arms as opposed to the 1.7 ratio roller rockers the Cobra had. If you find one of these motors, a stock 85-93 HO cam is actually an upgrade. 91-92 Cougars/T-birds had the HO cam.
The Explorer 5.0 was in Explorers and Mountaineers from '96-2000. 96 had GT-40 heads (the normal ones -- not the "P").The P heads were introduced halfway through the '97 model year. The issue with the P heads is the spark plug location and how it can interfere with exhaust header tubing. the HO cam is an upgrade over the Explorer cam as well. An Explorer/Mountaineer motor really wakes up with the HO cam and some 1.7 raio rockers.
There is also the F-150. E7 heads and 19 pound injectors BUT tiny flat tappet cam and the old school 302 firing order (non-HO) until '94, which was the first year for Mass Air in an F-150. All previous years were Batch fire Speed density -- not even SEFI Speed Density like the cars.
As far as whether or not a certain cam will work with X heads and Y pistons:
PISTON TO VALVE CLEARANCE CHECK PROCEDURES:
Piston to valve clearance is the relationship is just that, the distance from the valve to the piston during the most critical time in the engines cycle, that time is the "overlap". No other time during the engines cycle is the piston closer to the valve than in the overlap. Overlap occurs at the end of the exhaust stroke and the beginning of the intake stroke. This is the time when both the intake and the exhaust valves are open simultaneously.
A lot of people have used the max lift number when calculating piston to valve clearance and that is probably the single worst method. When the valve reaches it's maximum lift point the the piston is actually furthest away traveling down the cylinder bore drawing the intake charge in. The minimum clearances commonly used are .080 on the intake valve and .100 on the exhaust valve. For people using an aluminum rod it's a good idea to allow more clearance as the aluminum rods stretch when in operation.
To use the clay method take a 1/4th inch amount, cover the valve reliefs on your piston and rotate the engine one full cycle. Make sure it's 2 revolutions past top dead center. Take the head back off and peel the clay away. The best benefit of clay is that you can use an x-acto knife and cut it into sections and measure exactly where the thinnest area is, if there is any. Remember .080 and .100 minimum thickness.
The next method takes a little practice but is great if you don't want to take the heads off the car, although it will be necessary to replace the intake and exhaust valve springs on one of the cylinders. It's best to use a checking spring, but if you don't have a dedicated light weight spring, take a trip to your local hardware store. Remember the spring only has to have enough pressure to keep the valves fully closed and return an open valve back to it's closed position.
Now you want to adjust the rockers to zero lash. What is important here is if you are using a hydraulic type cam, whether it be a hydraulic roller or flat tappet hydraulic cam. Do NOT preload the lifter. All you want to do is take all the movement out of the pushrod WITHOUT collapsing the plunger in the lifter. Make sure you do this adjustment when the lifter is on the base circle of the cam which is at top dead center on the compression stroke.
You will need feeler gauges set to 0.100 thousandth's. Start with your piston at top dead center and rotate one full revolution in normal operating rotation. The piston starts traveling back up the bore, the exhaust stroke starts to occur, and the exhaust valve will start opening. Watching the valve train you will notice the exhaust valve opening till it's fully open. As you are approaching top dead center you will notice the intake valve starting to open before the exhaust valve is fully closed. This is the area of overlap, usually about 10-15 degrees before and after top dead center. Both the intake and exhaust valves are open and the piston is near the top. During this overlap point is when you want to measure the piston to valve clearance.
The piston is so close to to the top that you can push down on the nose of the rocker and actually feel the valve making contact with the piston. Now; with your feeler gauge set to 0.100, insert the feeler gauge between the valve stem tip and the rocker arm. If you can insert the gauge at 0.80 for the intake and 0.100 for the exhaust then you have enough piston to valve clearance.
It may take you some trial and error before you can identify the precise overlap period at which you need to check the clearances, but this is a good way for someone that does not want to take off the heads.
I highly suggest you go through the steps above several times, it is VERY easy to miss the overlap, resulting in very inaccurate measurements. Work slow and this process can be accomplished by just about anyone.
Final note, if your measurements are say less than 0.10, for example there is .090 clearance on the intake you can retard the camshaft and play around with that but remember that will also affect performance characteristics of the cam.
Hope this helps
