My story n cosworth rebuild
19-03-2010, 10:19 PM
#1
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My story n cosworth rebuild
Iv always wanted a cosworth , having nufink but fords all my life. Starting with a fiesta, moving on to escorts n orions n finally to sierras. i must have a thing 4 old bangers lol.
I dnt hav many pics of my old cars but here are a few....
My old orion had a rs1600i engine in it
i had this when i was 18.
Then came my 1st sierra...
This was a 2l pinto.
While driving this i got banned which ment i had no car 4 a long while
So when i got my licence back i wanted my sierra back.
My m8 at work at d time simon took me 2 look at a 2l dohc we found, itd only had 2 owners! and had been kept in a garage all its life. it was standard when i bort it but very clean.
So after a bit of work she became my pride and joy...
I dnt hav many pics of my old cars but here are a few....
My old orion had a rs1600i engine in it
i had this when i was 18.
Then came my 1st sierra...
This was a 2l pinto.
While driving this i got banned which ment i had no car 4 a long while
So when i got my licence back i wanted my sierra back.
My m8 at work at d time simon took me 2 look at a 2l dohc we found, itd only had 2 owners! and had been kept in a garage all its life. it was standard when i bort it but very clean.
So after a bit of work she became my pride and joy...
Last edited by mark needs help; 20-03-2010 at 09:38 AM.
19-03-2010, 11:29 PM
#2
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I then got to the stage where i was toyin with the idea of throwin a cozy lump into it. But with abit of research i soon realized itl prob cost me more 2 do this than 2 go n buy the real thing.
so i did.
I was well pleased
Only on stage 1 but thats all i wanted. Cudnt wait 2 take it out.
So I did and i had a little accident with the back wheel and the kerb!!!
The rd was abit slippy and i was abit trigger happy.
This is where the trubble starts lol.
After a few parts and the wheels off my old car she was gd 2 go again....
so i did.
I was well pleased
Only on stage 1 but thats all i wanted. Cudnt wait 2 take it out.So I did and i had a little accident with the back wheel and the kerb!!!
The rd was abit slippy and i was abit trigger happy.
This is where the trubble starts lol.
After a few parts and the wheels off my old car she was gd 2 go again....
Last edited by mark needs help; 20-03-2010 at 09:46 AM.
so jus be extra cautious! 
19-03-2010, 11:47 PM
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At this stage i knew f all about the cosworth engine but this was soon 2 change....
2 weeks went by and i knew it wernt running quiet right and i broke down n had 2 get recoverd. the coil had gone down. so i changed it
2 weeks went past and it broke down again.!! can u see a pattarn here ??!!??. Only a cosworth.
I had no spark but the coil was working. After a bit of messing i got a new ignition amp and it started again
Another few weeks went by n it still wasnt running quite right. on light throttle itl boost ok but on full it wud miss fire.
Guess wot happend next?......... yes it broke down
After getting it home again me n tom spent prob about 2 weeks on it. he was sure it was just a bad wire. we cud get it to start but it was massivly overfueling n missfiring.
After seeking help on here somebody told me 2 to make a led light to plug into the ecu and read the flash codes. it gave me a 3-3 code which ment and open map sensor.
So i went n bort 1 n success
I droped the oil n changed the filter n plugs. it ran but still not quiet right. still missfiring on full throttle.
so i took it to coley n rex some1 iv met off here local.
straight away they told me my turbo was plumd up wrong!!!!!
5 mins lata they sorted it out for me and it held 1 bar lovely
cheers guys
You can see in this pic my turbo n amal value was plumb up wrong from day
it was at this time a noticed a slight knocking noise top end.............
2 weeks went by and i knew it wernt running quiet right and i broke down n had 2 get recoverd. the coil had gone down. so i changed it
2 weeks went past and it broke down again.!! can u see a pattarn here ??!!??. Only a cosworth.
I had no spark but the coil was working. After a bit of messing i got a new ignition amp and it started again
Another few weeks went by n it still wasnt running quite right. on light throttle itl boost ok but on full it wud miss fire.
Guess wot happend next?......... yes it broke down
After getting it home again me n tom spent prob about 2 weeks on it. he was sure it was just a bad wire. we cud get it to start but it was massivly overfueling n missfiring.
After seeking help on here somebody told me 2 to make a led light to plug into the ecu and read the flash codes. it gave me a 3-3 code which ment and open map sensor.
So i went n bort 1 n success
I droped the oil n changed the filter n plugs. it ran but still not quiet right. still missfiring on full throttle.
so i took it to coley n rex some1 iv met off here local.
straight away they told me my turbo was plumd up wrong!!!!!
5 mins lata they sorted it out for me and it held 1 bar lovely
cheers guys
You can see in this pic my turbo n amal value was plumb up wrong from day
it was at this time a noticed a slight knocking noise top end.............
Last edited by mark needs help; 20-03-2010 at 09:48 AM.
19-03-2010, 11:53 PM
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20-03-2010, 09:09 PM
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Too many posts.. I need a life!!
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god youve had some bad luck, dont give up though mate, it will be worth it in the end. It might be worth replacing all the sensors whilst the engines in bits to increase its reliability.
20-03-2010, 11:40 PM
#10
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Rex has sent the crank off 4 me, hopefully itl grind up ok as it is only on standard grind still.
So i went down Ians 2day. We striped n cleaned the engine down as much as we cud 2day. Thanx 2 Ian n rex 4 there know how n a big thanx 2 little sam who helped me alot 2 strip n clean it
Didnt have any probs really, 4 of the exhaust stud bolts had previously been snapd off but coley sorted that.
The pistons looked fine when we pulled them out , considering there original n its dun 120000.
As im not aiming 4 big power we will reuse these n i ent really got the cash either 4 new 1s altho i do need 2 get hold of a conrod.
So i went down Ians 2day. We striped n cleaned the engine down as much as we cud 2day. Thanx 2 Ian n rex 4 there know how n a big thanx 2 little sam who helped me alot 2 strip n clean it
Didnt have any probs really, 4 of the exhaust stud bolts had previously been snapd off but coley sorted that
. The pistons looked fine when we pulled them out , considering there original n its dun 120000.
As im not aiming 4 big power we will reuse these n i ent really got the cash either 4 new 1s altho i do need 2 get hold of a conrod.
Last edited by mark needs help; 04-04-2010 at 06:44 PM.
04-04-2010, 06:41 PM
#12
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With the crank in the shop i set abot cleaning and painting a few things.
look at this 4 dirty !!!!......
.
After a gd clean and then sum paint
look at this 4 dirty !!!!......
.
After a gd clean and then sum paint
Last edited by mark needs help; 04-04-2010 at 06:46 PM.
04-04-2010, 06:55 PM
#13
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Next was the rocker cover. I wanted 2 keep it red, but i did wana change the colours abit so i was playing around with a few ideas. I wanted to keep the ford badge red as ive got red ford badges on back. So i figured id paint the other words grey like my car.
04-04-2010, 07:00 PM
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A few days lata a got a phone call, it was Rex. 'Your cranks dun mate' Safe az!!!!
It had beed grinded to .50 and he had got me the ACL race barrings all for Ł140!!!
Cant moan at that can i lol
It had beed grinded to .50 and he had got me the ACL race barrings all for Ł140!!!
Cant moan at that can i lol
04-04-2010, 08:40 PM
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So this weekend i went dont ians again and he started to put it back 2getha again.
The new barrings and crank went in. Then we cleaned up the pistons 1,2, and 4 then ian put them in.
As we still need a replacement con rod for piston 3 , that was as much as we cud do 4 now so then Ian told me 2 give the block a lick of paint.
Im pleased now were on the return leg, its goin back 2getha.
my next job is sorting sum money.
I need a con rod, a new oil pump and a full gasket set now then itlb well on d way. The problem is im broke as usual lol.
The new barrings and crank went in. Then we cleaned up the pistons 1,2, and 4 then ian put them in.
As we still need a replacement con rod for piston 3 , that was as much as we cud do 4 now so then Ian told me 2 give the block a lick of paint.
Im pleased now were on the return leg, its goin back 2getha. my next job is sorting sum money.
I need a con rod, a new oil pump and a full gasket set now then itlb well on d way. The problem is im broke as usual lol.
Last edited by mark needs help; 04-04-2010 at 08:41 PM.
05-04-2010, 03:26 PM
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i got a few more things cleand n painted 2day with my day off b4 i go back 2 work.
Thats flint grey paint again.
Iv got 2 wait a few weeks now 4 sum more money so il just clean n paint wot i can in the mean time
05-04-2010, 05:17 PM
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05-04-2010, 05:36 PM
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haha yeah i know that feeling, im rebuilding my brothers old moped for something to do atm, i cant drive at the moment so i get withdrawel symptems, hence why i took on the bike, but i have gotten that bad that i wont re-fit a part untill it is absolutly spotless and has been polished.... it could have been done by now if i jusrt gave the body panel as quick wash but hey ho...
13-04-2010, 09:30 PM
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Not much 2 report this time. Spent all day sat down coleys just cleaning off all the layers of shit on more conponents 
. hard work man.
120,000 miles of dirt and crap man!! Got 2 b dun tho.
then got a few more painted up.
Just waitin on sum money man doin my head in lol
. hard work man. 120,000 miles of dirt and crap man!! Got 2 b dun tho.
then got a few more painted up.
Just waitin on sum money man doin my head in lol
13-04-2010, 09:52 PM
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good to see your not giving up, ive had loads of trouble with my sierra but the joy of rebuilding it is knowing that its done properly and you now its not going to happen again any time soon
14-04-2010, 12:57 PM
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I dnt realy wana say the reg m8.
19-05-2010, 07:49 PM
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Sorry its been a while since the last up date. i havnt had internet
But anyway ur b glad 2 hear the engine is back in n all is sweet!!!
Big thanx 2 Coleyst200 , rex n little sam. The cosworth experts lol:king :: clap:
But anyway ur b glad 2 hear the engine is back in n all is sweet!!!
Big thanx 2 Coleyst200 , rex n little sam. The cosworth experts lol
:king :: clap:
16-07-2010, 08:17 PM
#36
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So its been a gd few weeks nows. Shes ran in, nice n steady 2 start with, dun nearly 3000 miles now been all the way 2 bognor n back and alls gd.
Shes had a oil change n set the boost and it hasnt miss a beat.
Since then just been tryin to tidy up wires , hoses, jub clips ect,ect...
Next job now is the diff, (apart from the heater matrix that went on holiday lol) its still fucked from the bang.
it drives ok, just bangs when engaiging gears n it wines on cumdown.
Also over say 100 it vibrates the whole car so its proper fucked like lol.
I cud get a bearing kit for it or just get another 1? wot do u think?
Wud any standard sierra diffs b anygd just 4 road use?
thanx
.Shes had a oil change n set the boost and it hasnt miss a beat.
Since then just been tryin to tidy up wires , hoses, jub clips ect,ect...
Next job now is the diff, (apart from the heater matrix that went on holiday lol) its still fucked from the bang.
it drives ok, just bangs when engaiging gears n it wines on cumdown.
Also over say 100 it vibrates the whole car so its proper fucked like lol.
I cud get a bearing kit for it or just get another 1? wot do u think?
Wud any standard sierra diffs b anygd just 4 road use?
thanx
16-07-2010, 09:11 PM
#37
no a standerd diff will not go on . and there is a sierra in hoppers in aston for your heater mark . i need to do that leak soon as well . and the thing with the car vibrateing again i need to see the car as when you first had it you put it over a kerb and bent a lot of stuff so you no my number and were we are on a satday . looking good with the new pipes
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