Well where do I start... Basically I have bought the sapphire cosworth that is mentioned in the recent post with number 4 oversize piston. Here is the post

https://passionford.com/forum/ford-s...e-my-luck.html

https://passionford.com/forum/genera...eful-guys.html

I am planning on doing the work myself as a project after speaking to James at MSD.

I am a mechanical fitter (marine not automotive) of 11 years and I have stripped and rebuilt a cosworth in the past but I had a full documented wallet with photos with a lot of helpful information.

After speaking to James @ MSD (very helpful chap) I thought to myself I might as well do the work myself. He said that he would be happy to help through out the engine strip and rebuild but any additional information/photos would be grately appreciated so that I can get this done as quick as possible.

In all fairness I have not had a problem since buying it and no water loss but now I know there is a problem I want it sorted. (OCD possibly)

Many thanks

Steven

 

All I would say is, plenty of zip lock freezer bags, and digi camera are your mates.
They have to be about the most simple engine going to strip and rebuild, when rebuilding you of course have the option of various tweaks, a major consideration is what HG to use, what make of parts etc for bits you need, don't be scared by the cossie badge they're a doddle.
I put everything in the tesco freezer bags, just rebuilt mine after 200,973 miles, so they can last if looked after.
tabetha

 

as said zip lock freezer bags are your best friend, and if you've done it once it will all come back to you
good luck keep us posted

 

tomma gutted mate but it'll be sweet as when its finished ive got the 2 thick cosworth manuals like if i can find them there bound to help you just look after them haha ive heard the very rare

 

Many thanks. I am planning on running the car for another month then hopefully making a start on it. Yeah good ide with the freezer bags. Thanks again.

If there are any particular arear to look out for then please let me know.

Thanks again

Steven

 

Cheers Scott lad. Like I say its been fine since getting and drove it every day but now i know there is s problem I am gonna get it sorted. Plus it gives me a hobby instead of going out on the drink.

We will have to go out for a dodge before I strip it though

 

haha aye no bother mate. i might come and have a look if you dont mind because i wouldnt mind learning how to do bits on mine myself and i know alot of the lads ive met from the meets ect would be happy to help you out if you become stuck

 

Spot on mate thats sound. More help the better really mate. LIke the lads have already said as long as I take plenty photos I should be sweet. Surely if I can build a 3 million quid subsea robot I can rebuild an engine haha...!!!

 

Piece of piss to do mate, theres not a lot to them. If your mechanically competent, which you obviously are, then you'll have no bother

 

Cheers BigErn. If I get any problems throught the rebuild i'm sure people on here will be happy to help...

 

Well chaps I have decided to start the car next week. While she is in bits the engine bay is also going to get a make over. I'm thinking blue rocker cover, blue header tank, blue swirl pot and catch tank, blue strut brace etc etc to match my hoses?? What you chaps think???

 

Too much blue for me, but if that's your thing go for it, only thing I'd say is consider just doing the engine first, get back running then do the other bits ?, may be worth considering.
tabetha

 

Well unfortunatly the garage which I was gonna be using isnt free until the weekend so the repair aint gonna be happening until next week. Suppose it gives me time get all of the necessaries together? Once started I will take some photos and keep updated.

Cheers

 

good luck, i have just finished my rebuild last week, litteraly stripped the engine to its last nut and bolt, cleaned and painted everything , looked mint when it was done and drives superb very satisfying

 

That looks sweet mate very nice..

 

The best advice i can give is keep everything in order of where it goes and keeping it clean is the most important thing you can do for it (especially the block oil galleries) As above, i always paint blocks/heads etc, does make them look nicer.

 

Well then..!!!! I have started the strip down and my intentions were to remove the pistons without removing the engine i.e strip top end and bottom end leaving the block and dropping piston.

BUT!!! Before I started to strip the bottom end I just thought I would have a check of the piston protrusion myself. I measured this using a calibrated DTI Clock gauge AND there is fook all wrong with number 4 piston.

My results were. Number 1 piston + .70 above block
Number 2 piston + .68 above block
Number 3 piston + .70 above block
Number 4 piston + .74 above block

As you can see from my results there is very little difference..

SO...... Where do I go from here. Can anyone recommend what gasket should be used with this sort of protrusion.

(PHOTOS TO FOLLOW)

Many thanks Steven

 

 

 

 

 

Any help would be appreciated

 

i havent got a clue mate but hope you get it all sorted mate still a stunner of a saff its only going to get better!

 

I am planning on rebuilding my engine on Monday/Tuesday. I have the yb0261 head gasket which I have been informed should be good for my motor.

Tha car has a 200 block and going to be running approx 380bhp. Could anyone help me with torque settings please as I am unsure what the correct procedure is.

With h the car having the 200 block and not the 205 does this matter?

Many thanks. Pics of new engine bay up soon.

 

Have you changed the pistons then or just re-fitting the head?

 

I strongly advise getting a manual, they've helped me on countless occasions.