Old Aug 11, 2009 | 11:19 PM
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cosimworthit
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Joined: Nov 2008
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From: Sideways
Default Cosworth 2wd keeps pressurising after 3 rebuilds help urgently needed

Help Urgently Required at the end of my tether

I decided after seeing a rebuilt engine for sale to treat my car to a fresh engine so i didnt have to worry about it going bang.

Well heres my story and your help would be much appreciated.

Engine 1 Head rebuilt with new guides valves oils stem seals and a skim block rebored to 0.5 with new mahle pistons all done at a reputable garage with receipt. Fitted small escos head gasket Happy days slipped her in and ran with cheap oil for 150 miles and no antifreeze. Changed oil added antifreeze done another 50 miles. Spotted a bit of smoking from the t34 and took front pipe off to see a smear of oil in the turbo intake. Took it to a tuner who said seal were probably going on it sourced a sencond hand unit with little miles on it. Took it easy for a few miles to check all ok took it out for a session and with in 10 mins of hard driving she spat all her water out and done a head gasket. This overheated as well so got it home stripped it down sent head away and found a crack in exhaust port 3 behind a bottom stud which was removed for the skim.
Welded and pressure tested light skim block inspected all ok fitted back up this time with a group a reinz gasket. Caution taken so new temp sender fitted,new rad fan sensor,new therostat,new water pump and temp guage fitted. Started her up and all crisp again took it down the road did a few miles and gave her some boost within seconds spat the water out and majorly done the head gasket this time blowing every port chamber the lot.
Pulled her back apart and found a crack between three and four in the block thought yippie at least i know the problem now. Found a breaker with a rebuilt short motor again with a receipt 0.5 fresh engine done 5k put my head on from the old engine with a group a reinz started her up and again sweet drove it all the way to ford fair taking it easy and noticed a slight missfire. Got it home cleaned dizzy and plugs found one of the scres ontop of the plugs loose tightened it up and took her out we were at full boost for a few seconds when i heard a loud bang from under the engine it had blown a pipe off the inlet manifold which it has done a few times evey since i have changed the engine. Fitted her back up with a cable tie off we went again within 4 miles of heavy boost max 18psi she spat the water and done another head gasket.


Help help help

To summerize the only thing remains on the car original is alloy pace rad which i had checked for blockages at a rad shop as water was a bit brown from original lump.

Only done a head gasket since this turbo was fitted and this still remains

Still using head form first engine i bought and when pressure tested only done cold not hot.

Run stage 3 currently boost turned down to 18psi ever since first engine fitted untill happy and was going to get it set up.

Keeps blowing off inlet pipes like to the 3 bar map sensor and had to cable tie them all up as i did one another would blow off and so on. When under full boost!!!!

Could the turbo have a crack in exhaust side and be leaking and pressurising water system

Could it be the head when warm a crack opening up and wasnt spotted because pressure tested when cold!!!!

Am i unlucky and got another cracked block!!!!!

Please someone help whats the best way to get closure once and for all as running out of money now and can only afford one more fix then i am going to have to sell up!!!! or break


Cositsnotworthitanymore!!!!!!

Sorry for any spelling or bad grammer as its late and i am falling asleep

Last edited by cosimworthit; Aug 12, 2009 at 04:48 PM.
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