Re: Zetec turbo, 7 years on... [update Pg2]
Posted: Sun Mar 29, 2020 12:51 am
Hi Guys, another update...
I've decided to take Matts advice and replace the big-end and main bearing shells and the piston rings. If I've gone this far, I might as well go all the way!
I'll total up all costs at the end but the latest expenditure included piston ring set at £62, big-end shells £25, mains £36 and the front+rear crankshaft oil seals £21. Not too bad.
Crankshaft removed, and then the main bearing shells removed.
You can see the under-piston oil spray jets. These are only fitted to the 2.0 litre zetec engines and help cool the pistons. I removed the jets and soaked them in parafin to clean them.
The old bearing shells
On the left are the 10 crankshaft main shells, and on the right are the 8 con-rod big-end shells. Some of the shells were scored so a good shout to renew.
New shells and rings.
Fitting will be later...
Sump
I'll reuse the Raceline sump from the old silvertop engine. Nice bit of kit. Gave it a clean up... you can see the pick-up pipe, and then it has an aluminium cover that bolts over the top (to reduce oil surge I guess).
This sump should fit fine, but there is one thing I have to do... The blacktop engine has a windage tray incorporated into it's sump - which I'm not using. So, I'll have to make the silvertop windage tray fit. On the old silvertop engine, the windage tray is attached to the engine block by 4 studs on the block...
Windage tray on old silvertop engine, showing mounting studs
However, the Blacktop zetec doesn't have these studs - (all the bearing caps are held in place with bolts, whereas silvertop uses some studs & nuts).
So, unable to mount windage tray to the engine block, I can instead mount it to the Raceline sump. I made some aluminium spacers up, drilled 4 holes in the anti-surge cover, and bolted the windage tray to this cover.
The whole thing can then be screwed into place in the bottom of the sump. Looks alright - lets hope it clears the crank!
Painting the block
I fitted a 40mm stainless steel core plug to blank off the old breather outlet.
Sanded and Jetwashed the block, degreased, metal prep treatment then 1 coat of engine block paint.
I've decided to take Matts advice and replace the big-end and main bearing shells and the piston rings. If I've gone this far, I might as well go all the way!
I'll total up all costs at the end but the latest expenditure included piston ring set at £62, big-end shells £25, mains £36 and the front+rear crankshaft oil seals £21. Not too bad.
Crankshaft removed, and then the main bearing shells removed.
You can see the under-piston oil spray jets. These are only fitted to the 2.0 litre zetec engines and help cool the pistons. I removed the jets and soaked them in parafin to clean them.
The old bearing shells
On the left are the 10 crankshaft main shells, and on the right are the 8 con-rod big-end shells. Some of the shells were scored so a good shout to renew.
New shells and rings.
Fitting will be later...
Sump
I'll reuse the Raceline sump from the old silvertop engine. Nice bit of kit. Gave it a clean up... you can see the pick-up pipe, and then it has an aluminium cover that bolts over the top (to reduce oil surge I guess).
This sump should fit fine, but there is one thing I have to do... The blacktop engine has a windage tray incorporated into it's sump - which I'm not using. So, I'll have to make the silvertop windage tray fit. On the old silvertop engine, the windage tray is attached to the engine block by 4 studs on the block...
Windage tray on old silvertop engine, showing mounting studs
However, the Blacktop zetec doesn't have these studs - (all the bearing caps are held in place with bolts, whereas silvertop uses some studs & nuts).
So, unable to mount windage tray to the engine block, I can instead mount it to the Raceline sump. I made some aluminium spacers up, drilled 4 holes in the anti-surge cover, and bolted the windage tray to this cover.
The whole thing can then be screwed into place in the bottom of the sump. Looks alright - lets hope it clears the crank!
Painting the block
I fitted a 40mm stainless steel core plug to blank off the old breather outlet.
Sanded and Jetwashed the block, degreased, metal prep treatment then 1 coat of engine block paint.