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Title: Cosworth 24v rebuild Post by Marc1978 on Oct 20th, 2010, 10:48pm Hi all, I posted on here a few days ago about converting my Scorpio Cosworth from auto to manual. Anyway, I have started the work but have noticed engine oil pouring out between the crank case and bellhousing suggesting the rear main oil seal is done for. With the timing chains starting to rattle and another rattle coming from the bottom of the engine when I put my foot down, it's time for a rebuild while I do the gearbox. What I would like to know is if someone can recommend where to go to buy a complete overhaul kit plus while I am at it, tubular manifolds and a set of uprated cams as well. All suggestions gratefully welcomed. Thanks. |
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Title: Re: Cosworth 24v rebuild Post by amigafan2003 on Oct 21st, 2010, 10:57pm The bits to rebuild these engines anymore are practically impossible to find, especially the timing chain items, best off trying to find a good 2nd hand unit I think. I think Piper do/did cams for the BOB. No one does off the shelf tubular manifolds - try someone like http://www.simpsonraceexhausts.com/ who should be able to fabricate a couple for you though. |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Oct 22nd, 2010, 10:46am Thanks for the heads up on the exhaust. Thankfully, I managed to strike it lucky with an overhaul kit from Specialised Engines based in Grays, Essex. They had on the shelf everything required to rebuild the engine from the bottom up although I'm not joking when I say it dented the wallet slightly - £1350 all in. |
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Title: Re: Cosworth 24v rebuild Post by Matt on Oct 22nd, 2010, 11:22am Just double check its for a scorpio 24v (BOB) and not the Granada 24v (BOA) most companies say they have the bits and when they turn up they are BOA bits which are no good for a BOB |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Oct 22nd, 2010, 11:26am Yeah I thought the same thing, but have been reassured they are all BOB parts. If not, they can go back for refund. |
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Title: Re: Cosworth 24v rebuild Post by L6ENY on Oct 22nd, 2010, 7:06pm Try Top Boss, they specialize in the BOB engine, and in house manifolds turbo's ect Cheers Len. |
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Title: Re: Cosworth 24v rebuild Post by Matt on Oct 22nd, 2010, 10:20pm top boss are a bit of a marmite company, you either like them or hate them, yes they have a huge knowledge of the bob and have helped people with different aspects of their builds, however they do have a bad press when it comes to customer service and some of the delivered parts they supply being not up to scratch. When dealing with them, their sales team seem to be the cause of most problems (recent thread on ford power), just use caution |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Oct 23rd, 2010, 10:27am I spoke to Top Boss regarding parts and although the lady there was very helpful in taking my contact details, it took the guy four days to call me back to tell me what I already knew. That said, he was very helpful on suggestions for upgrades though. |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Oct 30th, 2010, 10:09pm Thanks for all the advice given so far. The engine has been pulled to pieces and is now going back together, but I have hit my first problem. With pistions in the fist two bores at the front of the engine and the middle left if you are staring at the engine front on, when the conrods are tightened, the crank cannot be turned. If you have just the other three pistons in, you can turn the crank by hand with no problem. Any ideas as to why this might be the case? |
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Title: Re: Cosworth 24v rebuild Post by Scorpio_Mike on Oct 30th, 2010, 10:21pm Sounds like its binding on something... Big end bearing caps and con-rods are matched - are you sure you haven't got any mixed up ? Check main bearing caps are fitted correctly - should be numbered. Check piston rings are clear of any debris and the ring gaps are correctly orientated. Check the bearings are all the same spec. Have you had the crank reground ? Check the journals with a micrometer - maybe one or more got missed or ground incorrectly ? I would take it apart again, double check everything and reassemble very carefully. |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Oct 31st, 2010, 9:31am No mix ups, everything came out and went back in the same way and crank was fine (thankfully) so no regrind needed. |
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Title: Re: Cosworth 24v rebuild Post by gozz on Oct 31st, 2010, 9:53am Marc. Are you sure that you have got the big end caps the right way round on each rod.They are line bored and will only fit one way,I can't vouch for the 24v,but the caps usually fit with the bearing locating tag on the same side. GOZZ. |
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Title: Re: Cosworth 24v rebuild Post by Matt on Oct 31st, 2010, 10:04am could your rod bearing on that con rod be worn and its twisting slightly with just that pistion fitted? does the engine turn if all 6 are fitted? |
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Title: Re: Cosworth 24v rebuild Post by Mike H on Oct 31st, 2010, 1:13pm Does sound like a big end is too tight, as in tighten up the conrods bolts and then suddenly it won't turn no more (?) Could be jammed piston, I presume they all slide properly? |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Oct 31st, 2010, 5:07pm I figured out the issue. Two of the bearing caps were put in the wrong order. All fixed and the crank is turning a treat. Thanks for the all the ideas. |
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Title: Re: Cosworth 24v rebuild Post by Scorpio_Mike on Oct 31st, 2010, 8:37pm on 10/31/10 at 17:07:28, Marc1978 wrote:
Easily done :-[ |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Oct 31st, 2010, 9:00pm Maybe I should have bought the Volvo V50 my sister tried to sell me lol... |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Dec 14th, 2010, 7:05pm Well the engine is back together and in the car although for some reason I cannot for the life of me remember where these two brackets go. Please see link for picture... www.385north.com/brackets.jpg The one on the left is from the oil filter housing and the one on the right I am sure is from somewhere near the coil pack. Any ideas are very much welcomed. |
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Title: Re: Cosworth 24v rebuild Post by Highlander on Dec 14th, 2010, 8:50pm http://www.fordscorpio.co.uk/manual/engines/24v/24VDismantle.pdf Picture 11 shows it at the front of the engine on the NS cylinder head |
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Title: Re: Cosworth 24v rebuild Post by Matt on Dec 14th, 2010, 10:44pm One goes on the cylinder head like stuart says, the other on the bottom of the sump to support the oil cooler |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Dec 19th, 2010, 8:35pm Thanks for all the help guys. Much appreciated. No doubt there will be more questions. |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Jan 15th, 2011, 12:54pm Hi all, Everything is back together at last and the manual box is in a well. I connected the battery up and the ignition came on no problem and fuel pump could be heard as well, however, turn the key and the engine won't crank over. For now, as it's just been rebuilt, I haven't put the spark plugs or ignition leads back on as I just want to turn it over to pass the oil around and also, I haven't wired the two gearbox plugs up yet either or put the cruise control switches back on the pedal. Any ideas if I missed something and if I put a live direct to the starter to crank it, will that b****r the ECU? Thanks. |
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Title: Re: Cosworth 24v rebuild Post by Matt on Jan 15th, 2011, 4:17pm theres a start inhibit on the auto box wiring to stop you starting it in D or R on there range selector switch you will have a plug with 6 wires on it like so Start - 0 Rev - 0 - 0 - eng Rev - 0 - 0 - eng --- range selector plug Start - 0 link the 2 start ones together as for the direct live to the starter, if you just wanna pump oil around unplug the ecu and crannk it over, again leave the spark plugs out so the load on the starter is less and can crank over faster |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Jan 15th, 2011, 4:50pm Thanks for the diagram again Matt. Wired that plug in and the thing started a treat. Sounds like a bag of bolts and keeps cutting out but at least it starts now although I have an oil leak to contend with. I take it once I have wired in the other autobox plug (16 pins) then that will smooth out the ECU and stop the engine for cutting out? |
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Title: Re: Cosworth 24v rebuild Post by Matt on Jan 15th, 2011, 5:59pm hey marc check for any air leaks on the engine, the resistor will conenct to the same wiring plug as the start inhibit (to the eng cont wires), that will have some effect to but not much, you may have to sort the other plug out to smooth things out is the OD light flashing? you may have to mod the selector ice E and S buttons |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Jan 15th, 2011, 11:08pm Yep, the OD light is flashing unless I connect the two wires together and then it stays permanently on. Will definitely check for air leaks so once I've done the remainder of the wiring. Thanks again for the useful info. |
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Title: Re: Cosworth 24v rebuild Post by Matt on Jan 16th, 2011, 3:43pm The flashing OD light is saying theres a gear box fault, which it will as its not there any more lol to stop it flashing you will need to do all the wiring mods for the bypass / fooling all of which i put in the 24v manual topic in the how to do things section |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Jan 16th, 2011, 6:04pm Lol, might not get that far. Discovered oil coming out from both heads at the front corner. Not sure if it's the headgaskets or the timing cover. Either way, don't have the time to pull it to bits again so might just write the project off and sell the car for whatever it fetches. |
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Title: Re: Cosworth 24v rebuild Post by Matt on Jan 16th, 2011, 6:06pm did you re fit the small cap head type bolt at the front of both heads that joins it to the front cover? |
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Title: Re: Cosworth 24v rebuild Post by Marc1978 on Jan 16th, 2011, 6:19pm Yep, and I am thinking I will start with torquing those down some more. |
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