Restorations, Rebuilds & Projects. Restoring her to Concourse? Just getting her running again? Or got a mad project? This is your room.

Cosworth engine-rebuild

Thread Tools
 
Search this Thread
 
Old 01-04-2006, 11:56 PM
  #1  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default Cosworth engine-rebuild

Rebuilding my engine this winter. Started to smoke alot from the exhaust in August, after a few laps at Rudskogen, and a speedy trip home.

The engine had 350,2bhp, and was about 3 years old.




Hmm....



Old 02-04-2006, 12:00 AM
  #2  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

Inside of the engine did not look good












Rods were rubish, bought new (used) original ones.
Old 02-04-2006, 12:05 AM
  #3  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

The cause.


Crack in cyl. #1


Four cracks in all four pistons.


Piston #4 had a long crack in the top.
Old 02-04-2006, 12:11 AM
  #4  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

Some of the new parts.


New 200 block from Escort Cosworth.


Pistons from 4x4, machined low-comp etc. Gr.a. headgasket. ++


Modded elbow on the intake.
Old 02-04-2006, 12:17 AM
  #5  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

The engine is comming together, pics taken a few days ago.


ARP studs. Balanced crank and flywheel, wheight adjusted pistons and conrods.


Gr.a. oil squirt jets from mountune.




Ported.


Double valve springs.
Old 02-04-2006, 05:52 AM
  #6  
Turu3Dr
Wahay!! I've lost my Virginity!!
 
Turu3Dr's Avatar
 
Join Date: Dec 2005
Posts: 70
Likes: 0
Received 0 Likes on 0 Posts
Default

How many horsepower do you wanna get this time?

Good luck
Old 02-04-2006, 12:39 PM
  #7  
RS_Ant
PassionFord Post Troll
 
RS_Ant's Avatar
 
Join Date: Jul 2005
Location: Wolverhampton
Posts: 2,608
Likes: 0
Received 0 Likes on 0 Posts
Default

Good Luck And keep us updated

Trending Topics

Old 02-04-2006, 07:57 PM
  #8  
CosKev3
PassionFord Post Troll
 
CosKev3's Avatar
 
Join Date: Apr 2004
Location: Shropshire.
Posts: 3,047
Likes: 0
Received 0 Likes on 0 Posts
Default

Nice one

Looks excellent m8

Old 02-04-2006, 09:57 PM
  #9  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

Originally Posted by Turu3Dr
How many horsepower do you wanna get this time?

Good luck
Guessing the engine should be able to produce 450bhp. But I'm not shure I'm gonna drive with that high boost preassure.
Old 05-04-2006, 11:40 PM
  #10  
ital_cossie
Too many posts.. I need a life!!
iTrader: (2)
 
ital_cossie's Avatar
 
Join Date: Sep 2005
Posts: 695
Likes: 0
Received 1 Like on 1 Post
Default

very good!! waiting updates!!

Old 14-04-2006, 06:05 PM
  #11  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default















Old 16-04-2006, 11:02 PM
  #12  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default


Dirty!!


In.
Old 16-04-2006, 11:21 PM
  #13  
Paul_RS
PassionFord Post Whore!!
iTrader: (4)
 
Paul_RS's Avatar
 
Join Date: May 2004
Location: Bangor, Northern Ireland
Posts: 7,886
Received 35 Likes on 33 Posts
Default

Nearly finshed now?
Old 16-04-2006, 11:34 PM
  #14  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

Yeah, looking forward to it


[/img]
Old 17-04-2006, 08:58 AM
  #15  
cozzie4d
Too many posts.. I need a life!!
 
cozzie4d's Avatar
 
Join Date: May 2004
Location: Holland
Posts: 879
Likes: 0
Received 0 Likes on 0 Posts
Default

Very nice..
how many horsepower are you going for?
Old 17-04-2006, 11:01 AM
  #16  
lamb chops
PassionFord Post Whore!!
 
lamb chops's Avatar
 
Join Date: Apr 2004
Location: Waterlooville....near Portsmouth
Posts: 4,047
Likes: 0
Received 0 Likes on 0 Posts
Default

Very nice indeed!! Give that turbo housing a paint though wont you!
Old 17-04-2006, 11:41 PM
  #17  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

Originally Posted by cozzie4d
Very nice..
how many horsepower are you going for?
Guessing the engine should be able to produce 450bhp. But I'm not shure I'm gonna drive with that high boost preassure.
But it's a new turbo, seen very few dyno's with it, so I'm not shure how much it will give. Also got standard camshafts, they limit the horsepower too.

Either way, I am happy with 400bhp.
Old 18-04-2006, 09:34 AM
  #18  
Drjones
PassionFord Regular
 
Drjones's Avatar
 
Join Date: Jun 2004
Location: Durham
Posts: 371
Likes: 0
Received 0 Likes on 0 Posts
Default

coming on well now!

Bet you cant wait to drive it
Old 20-04-2006, 09:15 PM
  #19  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

Old 20-04-2006, 09:32 PM
  #20  
Charlie Chalk
Unknown.
iTrader: (1)
 
Charlie Chalk's Avatar
 
Join Date: Oct 2003
Location: ...
Posts: 50,873
Likes: 0
Received 1 Like on 1 Post
Default

Looking good
Old 20-04-2006, 09:43 PM
  #21  
rstoughy
PassionFord Post Whore!!
iTrader: (5)
 
rstoughy's Avatar
 
Join Date: May 2004
Location: onshore at the moment
Posts: 4,320
Received 0 Likes on 0 Posts
Default

Looking really good M8

@ the state of the original engine, im guessing that you caught that just in time before a major failure occured.

Will your bonnet shut with the oil cooler there? i've just had a nightmare fitting mine space was a big issue.

Keep them updates coming
Old 20-04-2006, 10:24 PM
  #22  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

Originally Posted by rstoughy
Looking really good M8

@ the state of the original engine, im guessing that you caught that just in time before a major failure occured.

Will your bonnet shut with the oil cooler there? i've just had a nightmare fitting mine space was a big issue.

Keep them updates coming
Thanks

The engine used 3 litres of water on 3km, couldn't see the road behind me, so it was kinda' hard not to notice Lucky the crank and head survived.

The bonnet do shut, with plenty of space
Old 21-04-2006, 01:21 AM
  #23  
Benni
Ban[B][/B]ned
 
Benni's Avatar
 
Join Date: Jul 2005
Location: The Pool.
Posts: 34,090
Likes: 0
Received 0 Likes on 0 Posts
Default

Looking good mate
Old 01-05-2006, 07:32 PM
  #24  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default



Old 01-05-2006, 09:22 PM
  #25  
rstoughy
PassionFord Post Whore!!
iTrader: (5)
 
rstoughy's Avatar
 
Join Date: May 2004
Location: onshore at the moment
Posts: 4,320
Received 0 Likes on 0 Posts
Default

What happened to the cam and valves M8?

Hope they are not from your new engine
Old 01-05-2006, 09:36 PM
  #26  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

Hehe, yes they are. The exhaustcam broke ten minutes after first startup.
Old 01-05-2006, 09:41 PM
  #27  
m.d.
I'm Finding My Feet Here Now
 
m.d.'s Avatar
 
Join Date: Apr 2005
Posts: 140
Likes: 0
Received 0 Likes on 0 Posts
Default

doh, what a pisser,
Old 01-05-2006, 10:07 PM
  #28  
rstoughy
PassionFord Post Whore!!
iTrader: (5)
 
rstoughy's Avatar
 
Join Date: May 2004
Location: onshore at the moment
Posts: 4,320
Received 0 Likes on 0 Posts
Default

£uck sake M8 sory to hear that

I had an exhaust valve break just below the collet about 30mins after start up on my Saff 4x4 a few years back just after id done the head. Was sitting ticking over and just conked out Trashed the engine.

Hope you can get it sorted without to much expense.




Here's a pic of what greeted me on removal of the head



Old 02-05-2006, 11:55 AM
  #29  
mk2rstaff
PassionFord Post Whore!!
 
mk2rstaff's Avatar
 
Join Date: May 2003
Location: aldershot
Posts: 3,577
Likes: 0
Received 0 Likes on 0 Posts
Default

very good what dates are rudskogen this year might be worth a cheap flight
Old 03-05-2006, 07:39 PM
  #30  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

Engine is up and running again
Old 03-05-2006, 09:11 PM
  #31  
rstoughy
PassionFord Post Whore!!
iTrader: (5)
 
rstoughy's Avatar
 
Join Date: May 2004
Location: onshore at the moment
Posts: 4,320
Received 0 Likes on 0 Posts
Default

Originally Posted by tr1ggerhappy
Engine is up and running again
Excellent M8, glad to hear it

Hope it werent to costly
Old 07-05-2006, 10:50 PM
  #32  
tr1ggerhappy
15000
Thread Starter
 
tr1ggerhappy's Avatar
 
Join Date: Dec 2004
Location: Norway
Posts: 34
Likes: 0
Received 0 Likes on 0 Posts
Default

The engine/car is finished, but the turbo is gone. Lots of smoke, and oil in the exhausthousing.
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
Billy_RS
Ford RS Cosworth Parts for Sale
4
13-09-2015 04:17 PM
Glenn_
General Car Related Discussion.
28
08-09-2015 07:10 PM
Adam Graham
Restorations, Rebuilds & Projects.
7
06-09-2015 06:04 AM
wheelwizardrefurbs
Technical help Q & A
2
05-09-2015 10:52 AM



Quick Reply: Cosworth engine-rebuild



All times are GMT. The time now is 10:17 PM.