Tell me what you think... CVH engine now WITH CLAY!
 

Disassembly and inspection:

http://junkengineering.files.wordpre...k-in-place.jpg
Block still in place

http://junkengineering.files.wordpre...od-bearing.jpg
Very nice con rod bearing’s… NOT!

http://junkengineering.files.wordpre...n-rod-caps.jpg
The 3rd con rod bearing “spinned” inside the housing (lower in the pic)
Thankfully there was no need resurface the housing!

http://junkengineering.files.wordpre...9/81-block.jpg
‘81 block in a ‘89 car…

http://junkengineering.files.wordpre...09/78-part.jpg
1978 part inside my engine!

http://junkengineering.files.wordpre...7/09/liner.jpg
Very polished cylinder liner with some scoring

http://junkengineering.files.wordpre...09/bad-cam.jpg
Camshaft in bad condition

Note that the clean metal was the only part of the cam in contact with the follower!


http://junkengineering.files.wordpre...picture007.jpg
This is why the cam was worn like that. 1mm less in the center of followers.

http://junkengineering.files.wordpre...dirty-head.jpg
‘90 EFI head

http://junkengineering.files.wordpre...oil-cooler.jpg
Oil cooler in wrong position

http://junkengineering.files.wordpre...with-valve.jpg
Had no idea that the oil cooler had a no-return valve built-in…

http://junkengineering.files.wordpre.../fly-front.jpg
http://junkengineering.files.wordpre...9/fly-back.jpg
A bit rusty flywheel

http://junkengineering.files.wordpre...water-pump.jpg
Water pump in an unbelievable state, note the rust blister’s on the vane’s surface!

http://junkengineering.files.wordpre.../09/clutch.jpg
Clutch (still good…)

http://junkengineering.files.wordpre...09/gearbox.jpg
Gearbox after cleaning a bit

http://junkengineering.files.wordpre.../old-parts.jpg
THAT’S a lot of part’s!

Feel free to post questions or comments! :top:

New parts from shop


After some time going around, store after store, asking prices for new parts (tight budget…), I finally found the “right” price at a nearby shop… Only after a fair bit of problems like I couldn’t get an oil pump ANYWHERE in this country (ford, parallel market, whatever…), and mixed head gasket set’s.

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New 0.29mm oversize pistons, gudgeon pins and rings

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0.5mm conrod big end bearings

http://junkengineering.files.wordpre.../075-crank.jpg
0.75mm crank bearings (the limit!!!) :cry: :cry:

http://junkengineering.files.wordpre...007/09/std.jpg
Another crank bearing

http://junkengineering.files.wordpre...water-pump.jpg
Much needed new water pump

http://junkengineering.files.wordpre...head-bolts.jpg
Normally when you ask, in a common shop, for head bolts they sell ford’s spec special stretch bolts. I got 10.9 strength common bolts… They are not designed to stretch at all, and are a bit on the heavy duty side… NICE!!!

http://junkengineering.files.wordpre.../new-parts.jpg
Some other important parts for a reconstruction, oil filter, oil pressure sensor and thermostatic water valve…

Part mods…


Continuing the porting started a year ago…

http://junkengineering.files.wordpre...0/damn-dog.jpg
When I was porting the head, I left it outside over a towel… The dog pulled the towel and head on floor!!!


http://junkengineering.files.wordpre...2nd-resurf.jpg
After the 2nd resurface, clean valves…

http://junkengineering.files.wordpre...orted-head.jpg
As the valve seats were a bit deep into the head, there was a very sharp step between the cc and the valve seat, so I’ve machined it to prevent flow losses.

http://junkengineering.files.wordpre...inlet-port.jpg
Inlet port straightned also slightly enlarged.


http://junkengineering.files.wordpre...ed-ex-port.jpg
Exhaust port roof raisened.

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Inlet valves after a 2 angle regrind, 45º seat and 30º above it.

The left one was polished with 50 grit sandpaper, then 280, 600 and finally 600 with WD-40.


http://junkengineering.files.wordpre...nlet-valve.jpg
Same treatment here… I’ve polished them not in search of more hp, but to prevent carbon adhering so easily.


http://junkengineering.files.wordpre...ve-2-angle.jpg
Same thing to the exhaust valves… Not so polished because the steel is much harder compared to the inlet.

http://junkengineering.files.wordpre...ened-pist2.jpg
http://junkengineering.files.wordpre...ins-weight.jpg
Note the lightened piston. I’ve managed to take 4 grams out but it still remained to heavy compared to rest of the pistons (weight in grams with the gudgeon pin)… :(

I’ve put them in order so that the rotating equilibrium is not very disturbed by different piston weight’s (not the order in the pic…)

http://junkengineering.files.wordpre...0/back-fly.jpg
http://junkengineering.files.wordpre.../front-fly.jpg
http://junkengineering.files.wordpre...-fly-front.jpg
About 600g were taken out of the flywheel (400g near the ring gear)

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Ground and polished crank (fillets respected)

Performance parts

http://junkengineering.files.wordpre...10/cam-kit.jpg
Since my budget is very limited, this section is quite small… :(


http://junkengineering.files.wordpre...007/10/cam.jpg
Schrick camshaft kit, with new valve springs and lower valve spring retainers

Cam info: 288º inlet/ 280º exhaust (28º-80º, 69º-31º)

Cam lift: 6,5mm (10,6mm at the valve)

Valve lift at TDC: 1,4mm, 1,8mm (important for good idle at low speed and the ability to pass in emissions test) below 1,9mm for 2 valve engines with hydraulic followers.

Very good machining (CNC), tight fit in head and lobes coated to aid break-in.

For those of you that never heard of this company, they are the makers of the Bugatti Veyron’s engine block and cylinder head (as many precision parts for F1, etc.)

And also the makers of this:
http://junkengineering.files.wordpre...erlegt1yx0.jpg
16 valve conversion kit for the CVH!

http://junkengineering.files.wordpre...ole-in-cam.jpg
Here’s one thing you don’t see everyday on a CVH cam, a hole in each lobe to lubricate the follower… Very nice!


http://junkengineering.files.wordpre...10/springs.jpg
The new valve springs are approximately the same geometry as the old ones.

http://junkengineering.files.wordpre...w-retainer.jpg
3,5mm spring retainer and guide

Watching this rebuild with interest!
I'm amazed at the 16V conversion for the CVH! Do you have any other information on it?
Keep up the good work! :top:

16v conversion
 

Yeah never knew you could get a 16v conversion kit, learn something new every day. Keep the pics coming, very interested :top:

:eek: :eek: :eek: :eek:

16v conversion

any more info?

:top: :top: :top: :top:

for a bit more info on the 16v CVH:

http://www.rs1600i.net/phpBB2/viewto...158320570ce63d


"Schrick engineerd them in 1984 and ford tested them in 2 fiestas in cologne and Saarlois. Schrick build 4 of the Zylinderheads. After a time of testing ford says that the dont make it, to Ford part, but still want to sell the heads over the tuning-shops (like eichberg or gerstmann). But this will never happens and schrick gave the order to ford to scrap all heads... One guy will put my head in his work bench, and gives me the head few years later...."

aside from the 16v subject, any comments on my rebuild???

:cry: :cry:

Coming along very nicely mate :top: :top:

Do you have any pics of the car?

Re: Tell me what you think... CVH engine rebuild
 

What part does it tell you that the cam is worn... it's not clear from the pic.

forgot this pics..... :DD:

http://junkengineering.files.wordpre...s-cam-base.jpg
1mm short in diameter...

http://junkengineering.files.wordpre...eel-to-toe.jpg
That’s 5,17mm of cam lift (should be 6,13…)!

Some pics of the car...

http://junkengineering.files.wordpre...arro-antes.jpg


http://junkengineering.files.wordpre...roca-caixa.jpg

Anyone would agree that its the right way to measure cam lift? :eek:

Of course it is the right way... But not the only right way..... :roll:

Some important verifications…

http://junkengineering.files.wordpre...ay-on-pist.jpg
I’ve put some children’s modeling clay on the top of the piston in TDC to measure:


-Squish area thickness (1,7mm)

http://junkengineering.files.wordpre...impression.jpg

-Valve distance to piston (minimum 1,5mm) ~5mm inlet, ~4mm exhaust


http://junkengineering.files.wordpre...valve-impr.jpg
Exhaust valve impression


http://junkengineering.files.wordpre...valve-impr.jpg
Inlet valve…

Work in progress!

nice work mate :top:

NEVER heard of that 16valve head before either :clap:

Maybe you know RST cam lift values, so I could check mine this way? Thanks :top:

really cant see the point in that 16valve head so you may as well donate it to me :top: :top: :banana: :banana: :top: :top:

yes, you can... :top:

That 16v head was available in 1984! that's the only point :top:

Hi there, If you want more details and information visit my homepage(the 16V is mine) www.rs1600i.de

nice

believe there was only ever 3 of them 16v heads made.... rare as fook!!

so if theres only 3 of these heads is there any other way to convert a cvh to 16V? zetec head for example as u can put a zetec bottom end on a cvh head so y not zetec head on cvh bottom end? plus hows the build going any new updates? and what sort of power and torque you hoping to get from this conversion. my 1600 cvh EFI is one that produces 108bhp so much more than that? i love my cvh but i really want some 16V power without chukin a 2litre zetec in like everyone else lol

Nice project :god: something different :king:

You'll be short a few oil feeds mate if you drop a zetec head on a cvh block;-)

fair enough but wold it be possible if you got the oil feeds put in? and if so what sort of power and torqe should i expect it runs 108 as standard =P

The oil ways are cast into the block mate.