Wes-Spec 4x4 Sapphire Cosworth
21-11-2010, 12:19 PM
#165
I've found that life I needed.. It's HERE!!
Thread Starter
I finished stripping down the block completely yesterday, and after I had removed the oil pump I found this:
Looks like this engine was doomed no matter what
I dont know which I would have preferred to be honest, dropping a valve or the damage that no oil would have caused to everything Either way it was never going to end well.
This was the revised version of their new 4x4 oil pump that was redesigned to stop the bung blowing out as documented in this post: https://passionford.com/forum/genera...oil-pumps.html Doesnt seem to have worked! Engine had only done 1200 miles and most of that was running in time!
Looks like this engine was doomed no matter what
I dont know which I would have preferred to be honest, dropping a valve or the damage that no oil would have caused to everything Either way it was never going to end well.This was the revised version of their new 4x4 oil pump that was redesigned to stop the bung blowing out as documented in this post: https://passionford.com/forum/genera...oil-pumps.html Doesnt seem to have worked! Engine had only done 1200 miles and most of that was running in time!
04-02-2011, 03:46 PM
#169
I've found that life I needed.. It's HERE!!
Thread Starter
It's getting there mate, got a EEC4 block block, new pistons, doing measuring and the machine work required on these at the moment, oil pump went back to cosworth and they replaced it with a new "cast" item, turbo went back to TT and has been repaired, gearbox is away being overhauled (dog rings are fubar!), lots going on really! Hopefully it will be back together and running before April, but i'm in no rush at the moment.
I'll post some pics of what i've been upto with it at somepoint soon
How's the Escort coming along?
I'll post some pics of what i've been upto with it at somepoint soon
How's the Escort coming along?
04-02-2011, 07:59 PM
#170
look forward to see it up and running again.The Escort has took a back stage as i bought the white saff that was on tony's ramp. wev'e now converted it to 2wd and made and fitted a 6deg beam for it, just need to do a few engine tweaks to it then all systems go on the Escort.
06-02-2011, 01:12 PM
#171
I've found that life I needed.. It's HERE!!
Thread Starter
look forward to see it up and running again.The Escort has took a back stage as i bought the white saff that was on tony's ramp. wev'e now converted it to 2wd and made and fitted a 6deg beam for it, just need to do a few engine tweaks to it then all systems go on the Escort.
When its all working again I'll be up to see uncle Tony
06-02-2011, 01:13 PM
#172
I've found that life I needed.. It's HERE!!
Thread Starter
Gearbox is away being repaired so I can't take any measurements, god knows how long that will be before I get it back, waiting for parts to be made in Austrailia
06-02-2011, 01:29 PM
#174
I've found that life I needed.. It's HERE!!
Thread Starter
I’ve been meaning to update this for a while but it’s not really exciting stuff:
Cylinder Head
Levelled the head up in both axis to get accurate readings:
I then lap in every valve by hand, clean it all up and then pour methylated spirit into the combustion chamber (I fit an old set of plugs for this):
I wait for 5 minutes or so and see where it’s leaking. I do this with no springs installed, just the weight of the valves are holding them down, the theory being if they don’t leak like this they will be perfect!
As you can see I have no leaks on the inlet side:
But it is leaking on exhaust valve in chamber 4:
So a bit more work is done lapping those 2 valves and then repeat the process until no more leaks.
I then measured the volume in each chamber. I place a piece of Perspex with a whole drilled in the middle over the chamber, applying the smallest amount of grease around the perimeter so it seals. Then I pour in the meths until it reaches the bottom of the hole in the Perspex:
Due to the repair work done I wanted to make sure no 3 in particular was the same as the others (which it was) 49cc per chamber.
Bearing Tolerances
Now I’ve got the replacement block and new bearings I could measure the clearances to make sure they were within tolerance, all mains and big ends (respectively) were the same measurements so I won’t bore you all with pictures of every one:
Mains:
Big Ends:
Inlet gaskets + Clean up!
I discovered that Cometic now do a gasket kit for the RS500 plenum so I promptly ordered one, I had previously made my own gasket for the throttle body (which worked perfectly) but on the elbow I used sealant which I was never very happy with.
When the kit arrived I knew something was wrong straight away. Elbow gasket fitted perfectly:
But the TB gasket was a bit small
A call to the supplier and they sent out the proper one:
When I stripped the engine after it died I put the inlet manifold and plenum in a box thinking I’d clean them up as and when. I knew there would be some oil in the plenum but it turned out there was about half a pint in there, along with quite a lot of piston and some other friends
Yep those bug chunks are part of the valve guides
The debris had all stopped at the bottom of the elbow, there was nothing in the throttle body or in the boost pipe thank goodness, trying to clean out the intercooler would have been a royal pain in the RS!
After a lot of elbow grease (and even more brake cleaner!) they are all clean again:
Cylinder Head
Levelled the head up in both axis to get accurate readings:
I then lap in every valve by hand, clean it all up and then pour methylated spirit into the combustion chamber (I fit an old set of plugs for this):
I wait for 5 minutes or so and see where it’s leaking. I do this with no springs installed, just the weight of the valves are holding them down, the theory being if they don’t leak like this they will be perfect!
As you can see I have no leaks on the inlet side:
But it is leaking on exhaust valve in chamber 4:
So a bit more work is done lapping those 2 valves and then repeat the process until no more leaks.
I then measured the volume in each chamber. I place a piece of Perspex with a whole drilled in the middle over the chamber, applying the smallest amount of grease around the perimeter so it seals. Then I pour in the meths until it reaches the bottom of the hole in the Perspex:
Due to the repair work done I wanted to make sure no 3 in particular was the same as the others (which it was) 49cc per chamber.
Bearing Tolerances
Now I’ve got the replacement block and new bearings I could measure the clearances to make sure they were within tolerance, all mains and big ends (respectively) were the same measurements so I won’t bore you all with pictures of every one:
Mains:
Big Ends:
Inlet gaskets + Clean up!
I discovered that Cometic now do a gasket kit for the RS500 plenum so I promptly ordered one, I had previously made my own gasket for the throttle body (which worked perfectly) but on the elbow I used sealant which I was never very happy with.
When the kit arrived I knew something was wrong straight away. Elbow gasket fitted perfectly:
But the TB gasket was a bit small
A call to the supplier and they sent out the proper one:
When I stripped the engine after it died I put the inlet manifold and plenum in a box thinking I’d clean them up as and when. I knew there would be some oil in the plenum but it turned out there was about half a pint in there, along with quite a lot of piston and some other friends
Yep those bug chunks are part of the valve guides
The debris had all stopped at the bottom of the elbow, there was nothing in the throttle body or in the boost pipe thank goodness, trying to clean out the intercooler would have been a royal pain in the RS!
After a lot of elbow grease (and even more brake cleaner!) they are all clean again:
Last edited by wes; 06-02-2011 at 02:58 PM.
27-02-2011, 09:40 PM
#180
I've found that life I needed.. It's HERE!!
Thread Starter
I got my replacement oil pump from Cosworth before xmas after taking back the faulty one, decided to strip it to do some of my own quality control due to what I found in the previous pump, luckily this one was swarf free!
Now I had all of my bits together in one place I dry built the engine and measured the compression ratio. First thing was to level everything up:
Then using a burette I poured in some meths until it was at the bottom of the spark plug hole, noting the amount used:
I then stripped it all down and pressure washed everything to remove all dirt + debris, then I masked off the block and gave it some paint to freshen it up a bit:
And thats were I left it today, paint on block needs to dry before I can do anymore on it, I will be assembling engine soon, hopefully it will all be back in the car and running in a few weeks!
Now I had all of my bits together in one place I dry built the engine and measured the compression ratio. First thing was to level everything up:
Then using a burette I poured in some meths until it was at the bottom of the spark plug hole, noting the amount used:
I then stripped it all down and pressure washed everything to remove all dirt + debris, then I masked off the block and gave it some paint to freshen it up a bit:
And thats were I left it today, paint on block needs to dry before I can do anymore on it, I will be assembling engine soon, hopefully it will all be back in the car and running in a few weeks!
great work wes
04-03-2011, 12:58 PM
#187
I've found that life I needed.. It's HERE!!
Thread Starter
Cheers fellas, I'll get there eventually
Gone bang again? I hope not as I haven't finished rebuilding it from the one and only time the engine has gone bang
09-05-2011, 10:53 PM
#190
I've found that life I needed.. It's HERE!!
Thread Starter
Time for a big update! Engine is built and in the car now, here are some assembly pictures
Ring gapping:
Studs fitted to block:
EEC-IV oil jets fitted:
Windage tray fitted with new oil pump:
Head on and torqued down:
Timing inlet cam:
RS500 inlet fitted:
Oil + Water lines fitted:
Turbo fitted:
Engine in:
Thought Id give it a bit of a clean too, doesnt scrub up too bad!
Engine fired on the button
Now for the running in period, again, joy
Ring gapping:
Studs fitted to block:
EEC-IV oil jets fitted:
Windage tray fitted with new oil pump:
Head on and torqued down:
Timing inlet cam:
RS500 inlet fitted:
Oil + Water lines fitted:
Turbo fitted:
Engine in:
Thought Id give it a bit of a clean too, doesnt scrub up too bad!
Engine fired on the button
Now for the running in period, again, joy
11-05-2011, 05:39 PM
#200
