Black 3dr Cosworth - Engine in & underside restored - done

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Re: Sierra 3dr Cosworth - 400bhp then nothing

Postby knuckles on Tue May 05, 2009 11:19 pm

gutted for ya fella :cry:

u have been lucky not to bend any valves ? or is that when the belt jumps etc ?
hope it works out ok for ya :)
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Re: Sierra 3dr Cosworth - 400bhp then nothing

Postby Brammer on Wed May 06, 2009 6:15 pm

knuckles :gutted for ya fella :cry:

u have been lucky not to bend any valves ? or is that when the belt jumps etc ?
hope it works out ok for ya :)


Well it turns out i was as lucky as what i thought, new cam fitted and tried and it's poorly bad, head coming off Saturday for a complete inspection - i think it's dropped valves so it's going to be costly i think :rolleyes:
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Re: Sierra 3dr Cosworth - 400bhp then nothing

Postby Brammer on Thu May 07, 2009 5:44 pm

We thought we'd give it another try -

Compression test shows:

1 - 150
2 - 150
3 - 150
4 - 145

Re-timed and started and appears to run right but it's tapping badly so it looks like followers but this is being comfirmed by someone. At least for now the head doesn't have to come off and a new set will be here on Sat morning thanks to Matt lewis

Also a couple of bits from AS arrived this morning to cheer me up - header and amal valve in pro series

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Re: Sierra 3dr Cosworth - 400bhp then nothing

Postby jayrs on Thu May 07, 2009 10:20 pm

they look spot on in black mate :Q

fingers crossed nothing else is wrong with the car mate
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Re: Sierra 3dr Cosworth - 400bhp then nothing

Postby jonboisescort on Thu May 07, 2009 11:07 pm

they look awsome :Q

sounds like u had a lucky escape lets hope nothing else crops up :) :)
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Re: Sierra 3dr Cosworth - 400bhp then nothing

Postby Brammer on Mon May 11, 2009 7:09 pm

Well its all sorted and the battery on charge -

What a mission trying to sort it out but first off we needed to know what caused the problem - was it me with a heavy right foot? or was it a mechanical failure?? will it wasn't me :lol:

It turned out the the oil wasn't pumping to the outlet side of the head so a blockage somewhere in there had caused the whole of the side to run dry resulting in oil starvation to the cam and lifters that causing the cam to fail.

The oil pumps to the head up the inlet side of the block and that side of the head was fine, it then runs across the front so we knew the issue was there as all 4 pots were dry - unblocked and filter removed - new oil added and a manual test of the pump showed a decent oil flow around the outlet followers :D

All sorted with new parts fitted :devil: shame it couldn't have been done last week as i had to go to Cumbria RS show car-less :( bring on Croft though :Q )
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby Turboboy67 on Mon May 11, 2009 7:21 pm

Good to read you've sorted it mate :)

Like you say though, typical that you missed the Cumbria RSOC regional day :rolleyes:

Fingers crossed now it behaves itself for the rest of the show season. :Q

:D
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby Minstral on Mon May 11, 2009 7:30 pm

glad its fixed mate, love the as pro series items
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby 1098 on Mon May 11, 2009 8:02 pm

Really nice car. The wheels match it to a T and as it's not sitting as high at the back looks more meaner.
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby FRSJON on Mon May 11, 2009 8:56 pm

very glad it wasnt a too a painful fix.... :) theres plenty more shows mate... :Q
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby jayrs on Mon May 11, 2009 9:46 pm

glad to hear its sorted mate, and not turned out to be a big problem :)
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby Dave G fsi on Mon May 11, 2009 10:11 pm

Glad to hear its all sorted now mate :aviator:
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby JamieFRST on Mon May 11, 2009 10:24 pm

Nice one, glad to hear everything is sorted. That as header looks great in black.
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby Brammer on Tue May 12, 2009 3:18 pm

Cheers lads gonna get it timed tonight before work then it's our meet tomorrow so i can give it a good run down the motorway, must get the wiring to the rev counter converted so i can get a true reading as i don't want more problems.

i really hope the car behaves all summer but i seem to have this feeling in the pit of my stomach that i have gone that one step to far in tuning the engine i really hope it's not goig to start failing parts one after another or it'll have to go.
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby MarkRS2K on Tue May 12, 2009 8:15 pm

the joys of owning a ford :D

glad its sorted tho :)
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby Brammer on Wed May 13, 2009 5:17 am

Well it's still tapping so it's got to come apart again and blown through as it sounds it could be blocked slightly as the oil level is very slightly down :x this will be the 9th time the cams have been out now it's getting tedious i tell thee :rolleyes:

I was really hoping we could sort it without having to remove the head to get pro cleaned :(
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby jayrs on Wed May 13, 2009 8:47 am

bugger :(

at least if you need to change the same again you could do it qith ya eyes shut, guess thats a slight upside to it :oooh:
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Re: Sierra 3dr Cosworth - fixed, just needs timing

Postby Brammer on Thu May 14, 2009 6:36 pm

All timed and running, a little tappy still after the engine has been flushed and it turned new oil black in less than 30 miles.

New 10w 40 in it and a little tappy but we'll see if they sort themselves out over the next couple of days, i think it needs driving to sort it.
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Re: Sierra 3dr Cosworth - all back together

Postby RS rob on Thu May 14, 2009 11:03 pm

fingers crossed for you mate
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Re: Sierra 3dr Cosworth - all back together

Postby jayrs on Fri May 15, 2009 12:23 am

get driving it mate :Q
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Re: Sierra 3dr Cosworth - all back together

Postby Brammer on Fri May 15, 2009 7:32 am

AAAAAAHHHHHHHH!!!!!!!!!!! Mega pisted off - as stated in posts earlier it was said that it's timed off the V in the pully, but then found out it's off the post - it wouldn't run on the post so back to the V now i'm being told go back to the post thats why it's tapping as the V is TDC for a pinto :x so i'll have to go back to the post and see what happens, but according to folk the valves would have been touching the pistons, hope not as we've been pushing 31psi through it and going pretty quick :rolleyes: well we'll see what today brings.
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Re: Sierra 3dr Cosworth - all back together

Postby - Danny Boy - on Fri May 15, 2009 11:00 am

Thats really not good!!! :( :( :(

I hope its not that bad! It would be better to check the pistons and valves for damage sooner rather than later though!

Keep us updated! Such a lovely car for it to happen to :(
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Re: Sierra 3dr Cosworth - all back together

Postby M1K3Y_B on Fri May 15, 2009 11:27 am

Not having the best of luck are you :(

Don't give up on it, it will be worth it in the end once its sorted :wink:
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Re: Sierra 3dr Cosworth - all back together

Postby jimmyesh on Fri May 15, 2009 9:02 pm

Crikey mate, you've been through the mill with this lately! :aaah: Sorry to hear of all the hassle with the cams etc, hope the valves/pistons aren't damaged - fingers crossed! :oooh:
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Re: Sierra 3dr Cosworth - all back together

Postby Brammer on Sat May 16, 2009 7:28 am

Well the finger crossing worked, timed up correctly and it's quiet as a mouse :Q

The conclusion to the whole ordeal is:

It's possible a piece of gasket sealant :x came off when the rocker was put on and cranked down and it's found it's way around the engine to where it must have got stuck in the head causing starvation to the whole of the outlet side and shagging my cam and lifters up - all cleaned off, completely blown through and refitted new parts and sorted

Next for the car is back to the bodyshop next week for front bumper, splitter, upper rear spoiler to be painted, arches rolled and trimmed & and new front crossmember fitted.

Next for the engine is air injectors.

But after a long hard think regarding my ownership i've decided that i'm going to sell the car on towards the end of the summer and take the jump into an RS500, it's a shame as i've just missed out on a 40k black one in mint condition.

More updates soon.
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Re: Sierra 3dr Cosworth - Big smiles today

Postby jayrs on Sat May 16, 2009 10:01 am

the AA paying out then mate?

selling it on.. cant you just make this one RS500 spec save selling up etc?
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Re: Sierra 3dr Cosworth - Big smiles today

Postby Ruishy1 on Sat May 16, 2009 10:51 am

:oooh: selling it already !
but tbh mate, im with you, an RS500 is just heaven :aviator:

You still need the arch roller ? trying to organise a family member to dig it out of the tool cupboard for me :lol:
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Re: Sierra 3dr Cosworth - Big smiles today

Postby Brammer on Sat May 16, 2009 3:06 pm

Jay it's not worth it really i may as well sell and buy the real deal, would have liked to keep this but i would prefer a white or moonstone 500

Ruishy1 :You still need the arch roller ? trying to organise a family member to dig it out of the tool cupboard for me :lol:


Desperate mate, if you could get it to me asap as i have the car in the bodyshop next week :wink:
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Re: Sierra 3dr Cosworth - Big smiles today

Postby jayrs on Sat May 16, 2009 8:41 pm

fair play mate, moonstone
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Re: Sierra 3dr Cosworth - Big smiles today

Postby MarkRS2K on Sun May 17, 2009 6:12 pm

fair enough matey, sounds like you get bored quickly! :)
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Re: Sierra 3dr Cosworth - Big smiles today

Postby M1K3Y_B on Tue May 19, 2009 2:03 pm

Glad to here its all good again :)

You have been through all the emotions with this car haven't you? :lol:
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Re: Sierra 3dr Cosworth - Big smiles today

Postby Brammer on Sat Jun 06, 2009 1:56 am

Right it's been in the bodyshop and the work is complete -

Front bumper - front splitter - rear spoiler - rear arches have been repainted

Front and rear metal arches have been rolled right back and arches trimmed to suit

New decal, pin stripe and wing badges all the original colour

New grill seal & bumpers strips

Pics to follow - picking my new turbocharged toy up Saturday :devil:
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Re: Sierra 3dr Cosworth - Big smiles today

Postby jayrs on Sat Jun 06, 2009 10:36 am

all the damage to the front panel etc from the AA done?
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