K7 TSS

hello people, where to start! lol well ive got a 2.1 zetec turbo was a fresh build it i haven't even driven the car yet! ive ran it in total about 2 hours.

i got our local machine shop to do me a re bore to allow the C20LET pistons to be fitted, polish the crank and fit the crank with new shells, i got my block back with the crank fitted with new shells and they supplied me with big end shells to fit the std ford rods milled out for the let pistons and a set of piston rings, i then fitted the pistons put the head on job done,

about 4-5 months i get the car running and umm the sump is filling up with swaff done 2 oil changes and comes out all gray! it ran sweat as a nut but now and then you would hear a slight bottom end rumble hold the revs up and it goes gets warm it goes of course things expand when hot.
so sumthing is wrong i striped it down and found the bottom end bearings to be wrecked the oil filter done its job as my brand new turbo is fine.

take a look at the pics what you guys thinking? im at a dead end now i think the machine shop left loads of swaff in my crank? ive got another 2.0 silver top and it a low mileage engine been ran for about 10 years and it looks brand new next to this one! take a look.











not looking to good! if you look closely you can see tiny little spots looks like swaff

and this is the shells on the low millage engine

Piston Broke

there is a size issue there i think mate or oil feed, my money is a size issue of the crank to big ends

LVC-Elvis

Hi mate, I'm and engine builder for Jag and have to say that is totalled, looks to me like regrind new mains and big ends. Had this kind of witnessing alot with prototype stuff, as you can imagine in development the shell sizes/tolerences are tweaked an awful lot in terms of microns to get the oil to film properly without causing resistance i.e. fuel economy. Strikes me its bearing tolerance based oil starvation, in these cases there is oil enough to stop the bearings/journals bluing up or burning but too tight to film and correctly lubricate. If you rebuild be sure to use a shop that it hot on tolerence, in the main you pay for the quality of machining you get.

You may get away with a polish on the crank journals, make sure the block, and everything is spotless befor eyou throw it back together, I would advise replacing the oil pump also!

Keep us posted

K7 TSS

thanks for the quick reply boys. yer im thinking they havent got the measurements right, they wore trying to say it was the top end, cam bearings gone pumping swaff in to the sump! i was goin mad the head is mint! im showin them it all in bits tomoz! yer im not going to use the oil pump im changing engine now goin 2.0 instead of 2.1 any one after a 86mm zetec silvertop block let me no!

Turbo Zetec

iTrader: (1)

looks like a bit of dirt in the oil tbh, could be from the machine shop, or even from your workshop depending on how long you left it apart for, before you fitted the sump. i wouldn't imagine it'd be a size issue, or a crank full of swarf if all they did was polish it. the grey oil could be from graphogen (http://www.graphogen.co.uk/), an assembly lube that's still fairly common.

if i were you, i'd get advice from another machine shop about how bad it is before you point the finger, but make sure its a trustworthy one. try looking for one in the FER (http://www.fer.co.uk/), or if the machine shop is part of the FER, then contact the FER for advice.

K7 TSS

engine was wrapped up in pallet wrap once built and then in the bay for a month while making the loom and getting it running, the oil thing in the oil is mashed up metal!

Turbo Zetec

iTrader: (1)

how long was it between you getting it back off the engine builder and you building it?

how much metal was in the oil? there doesn't look enough off the bearings to leave a massive amount in the sump. also, how do the main bearings look? any idea how the machine shop cleaned the parts? and did they remove all of the gallery bungs?

not taking sides here, just trying to get a better picture of where the problem arose

Turbo Zetec

iTrader: (1)

other things to consider - did you use oil or assembly lube when fitting the rods to the crank? how long was it between building it and starting it? did you oil the pump before fitting it? did you get the oil pressure up by cranking it over a while before starting it?