blacksofstichill Posted February 8, 2013 Share Posted February 8, 2013 I have to say a big thanks to my good friend Parky for getting me this job as it's for his Father-in-law's mint Cortina 1600E, it was removed to tidy up the engine bay and it's being given a full reconditioning including conversion to hardened valve seats suitable for unleaded. Here it is as delivered by Steve and Len - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0001.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0002.jpg Here's my little lad getting ready to help me strip the engine down, boilersuit on, cup of tea in hand and he's ready for work! - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0003.jpg The Flywheel was already off so it's ready to bolt the engine stand bracket on straight away - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0004.jpg Bolted onto the engine stand - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0005.jpg You can just see Alex working away at the other end of the engine with my Dad supervising in the background.....not too sure what Alex is actually doing though! - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0006.jpg Rocker Cover off - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0007.jpg Rocker Shaft and Pushrods removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0008.jpg Cylinder Head removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0009.jpg The Waterways in the head and block are quite badly blocked up - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0010.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0011.jpg This waterway hole was actually completely blocked until I picked a hole in it - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0012.jpg Crank Pulley and Timing Cover removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0013.jpg Distributor, Oil Pump, Fuel Pump and Engine Mount removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0014.jpg Other Side Engine Mount removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0015.jpg Engine Flipped over - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0016.jpg Sump removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0017.jpg Big End Caps removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0018.jpg Pistons removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0019.jpg Big End Shells are in good order which is always promising, they'll be replaced anyway but it means that the crankshaft stands a good chance of still being in good order too - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0020.jpg Big End Journals on the crankshaft are mint which is good as it means there's no need to regrind the crankshaft - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0021.jpg Timing Chain and Cam Sprocket removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0022.jpg Camshaft removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0023.jpg Crankshaft removed, the main journals on the crankshaft were also good, I'll add photos of those later - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0024.jpg Unfortunately, the bores had a bit of wear and some scoring, some of the scores are deep and not something you could hone out so even without measuring the amount of bore wear I could see it needed a rebore - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0025.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0026.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0027.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0028.jpg Link to comment Share on other sites More sharing options...
ganges Posted February 8, 2013 Share Posted February 8, 2013 here we go again, another great start to another great thread, this is bordering on wanting to go into the "HOW TO" section surley Link to comment Share on other sites More sharing options...
blacksofstichill Posted February 8, 2013 Author Share Posted February 8, 2013 Cheers, hope this one keeps you entertained like the last one! If any of the admin want to move the thread for any reason I'm happy with that, since I'm quite new to the forum I'm not sure of where I should be posting this kind of thing. Link to comment Share on other sites More sharing options...
blacksofstichill Posted February 8, 2013 Author Share Posted February 8, 2013 So with the bores being scored, out came the Boring Bar! This is a Van Norman 944 Boring Bar which is old but still accurate and reliable to this day, my Uncle used this all the time but this was the first time it had been used since he died so I'm sure he'd be happy to know it's still working. The Boring Bar clamps to the top of the engine block and clamps down with a bracket which locates on the underside of a bore, normally one which is 2 cylinders away from the one you want to rebore - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0029.jpg With the clamps still slack, you then lower the boring head into the bore and screw out 3 "cats paws" which centralise the boring head in the bore, at that point you can clamp the boring bar down tightly to the block - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0030.jpg After checking the availability of oversize pistons I decided to go for a 20 thou (0.020"/0.508mm) overbore. I do this in 2 cuts, one 15 thou roughing cut and then a 5 thou finishing cut. The boring size is set using a special micrometer unique to a boring bar which reads in the size it will bore at rather than just measuring the length of the cutting tool. The tool length and therefore cutting size is set by screwing the backstop screw in or out and locking it at the correct length - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0031.jpg With the tool set to the correct size, the "cats paws" are retracted back in the boring head, one of these "cats paws" is visible in this photo, about 1/3 of the way in at the top with a slotted screw in it. The cutting tool is then located and clamped into the boring head and it's ready to go - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0032.jpg Fired up, set to auto feed and it's starting to bore it out - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0033.jpg After the Roughing and finishing cut, the bore size is checked with the internal micrometer - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0034.jpg This boring bar cuts very well and gives a good cutting finish, although you can see the machining marks these will clean up with minimal honing and as such I only allow half a thou of extra material for honing, any more than that and you're giving yourself a lot of work for no gain in finish, honing is only intended to improve the bore finish and remove the high spots, not to remove large amounts of material. Here is the bore as it is straight after boring - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0035.jpg With all of the bores rebored it's the honing bar's turn and all of the bores are honed to finish them off - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0036.jpg The finished bores after honing - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0037.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0038.jpg All of the bores bored and honed and now the block is ready to be cleaned up in the waterways, cleaned up on the outside and painted - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0039.jpg Link to comment Share on other sites More sharing options...
bronze4door Posted February 8, 2013 Share Posted February 8, 2013 has that been rebuilt before or had the head changed because the earlier crossflow engines with the combustion chamber in head should have had flat top pistons and yours looke like they have a bowl in them as well as in the head the pistons with bowls in them are from the later crossflow engine is it a 681f or a 711m block, the cortina should be a 681f Link to comment Share on other sites More sharing options...
blacksofstichill Posted February 8, 2013 Author Share Posted February 8, 2013 Cheers for your interest, it's the original engine for the car and from what I saw when I stripped it ive no reason to think it has been rebuilt before, I'm confident it hasn't been in bits until I came along.It's a 681f block and has the bowls in the pistons as you've noticed, it does have very shallow chambers in the head too rather than being flat, as far as I can make out that's what a 1600e should be like but I know there are a lot of variations of crossflows over the years as you say. Link to comment Share on other sites More sharing options...
hicksy Posted February 9, 2013 Share Posted February 9, 2013 Another cracking thread here! I shall be watching this one like the last one Keep up the good work Link to comment Share on other sites More sharing options...
blacksofstichill Posted February 9, 2013 Author Share Posted February 9, 2013 Cheers! Glad you enjoy reading these. Link to comment Share on other sites More sharing options...
blacksofstichill Posted February 11, 2013 Author Share Posted February 11, 2013 Another update, this one is just to show the condition of some of the existing engine components and why they're being changed. Starting with the Cam and Followers - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0040.jpg Some of the followers are badly pitted like these ones - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0041.jpg The cam itself also has the same issue with pitting in some places, almost as if the surface was breaking up slightly in places, particularly near the edges - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0042.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0043.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0044.jpg Although the pistons have to be changed anyway because of the rebore, you can see they have some scoring marks above the top ring in some places - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0045.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0046.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0047.jpg So, here we have a box of new goodies to replace that lot - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0048.jpg Bottom End Gasket Set - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0049.jpg Top End Gasket Set - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0050.jpg Cam Followers - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0051.jpg Crank Bearing Shells - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0052.jpg Thrust Washers - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0053.jpg Timing Chain - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0054.jpg + 0.020" Oversize Pistons with rings - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0055.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0056.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0057.jpg New Old Stock Genuine Ford Chain Tensioner from our own Stock - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0058.jpg New Old Stock Genuine Ford Cam Bearings, again these are from our own stock and although they are dusty since they've been in stock for about 40 years they are brand new and unused - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0059.jpg And last but not least we needed a new Camshaft. None of my regular suppliers could offer a new one made from a blank, only regrinds. So after some discussion with Piper Cams I got them to make us up a Standard GT Spec Profile Cam made from a Blank - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0060.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0061.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0062.jpg Link to comment Share on other sites More sharing options...
Ahmotorsport Posted February 11, 2013 Share Posted February 11, 2013 Is cam bearing line boring something you can do? If so i envy you! Link to comment Share on other sites More sharing options...
blacksofstichill Posted February 11, 2013 Author Share Posted February 11, 2013 Is cam bearing line boring something you can do? If so i envy you! It's not something I can do unfortunately, not just now anyway but it's something I'd like to be able to do in the future for sure! Link to comment Share on other sites More sharing options...
blacksofstichill Posted February 13, 2013 Author Share Posted February 13, 2013 Another update on this, I degreased the engine block inside and out, flushed it all out, etc and mounted the engine block on the stand and cleaned it all back to bare metal. To be fair, Len had already cleaned it up very well so it wasn't as big a Job as it would normally be. I also sanded the casting slightly to try and smooth off the high spots - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0063.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0064.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0065.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0066.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0067.jpg We wanted to use the best paint possible for the engine block so after some research we came up with this - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0068.jpg It's supposed to be excellent stuff according to the reviews I'd read, doesn't sound like the healthiest of stuff according to the label though! - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0069.jpg 1st side of the block given a light 1st coat - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0070.jpg Second side ready to coat - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0071.jpg And again, given a light 1st coat - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0072.jpg This is how it looked after 1 coat, it was left to dry for 24 hours like that - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0073.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0074.jpg Then it was given a 2nd coat which makes all the difference - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0075.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0076.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0077.jpg With the paint left to dry for another 24 hours it was time to change the cam bearings, to remove the old bearings and refit the new ones I'm using this tool which was made back in the 70s when my Dad and Uncle first started to rebuild these engines - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0078.jpg It's an easy slip-in fit into the bearing and the shoulder catches the edge of the bearing - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0079.jpg You can then just tap the tool on the outisde of the block and it will push the bearing out - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0080.jpg Old Bearings Out - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0081.jpg New Bearings ready to go in - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0082.jpg Onto the fitting tool - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0083.jpg Front end bearing redy to fit, note the pencil mark on the top, this is a mark I've put on as a guide so that I can line the bearing up correctly with the oil holes in the block when I fit it - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0084.jpg Front End Bearing fitted - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0085.jpg Middle Bearing Fitted - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0086.jpg Back End Bearing fitted - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0087.jpg Link to comment Share on other sites More sharing options...
Naylor2006 Posted February 14, 2013 Share Posted February 14, 2013 Loving the work again, I like the element heater I can see, obviously dedicated to working all year round, unless its fked and is just there for storage. http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0063.jpg Kinda wish I hadnt just bought a new car and house, would love to have seen my 2.0 go for a rebuild, still undecided as to what to do with it. Link to comment Share on other sites More sharing options...
blacksofstichill Posted February 14, 2013 Author Share Posted February 14, 2013 Cheers, glad you're finding it interesting! Yeah, the heater there does work but I don't often use it to be honest, I've got a radiator in the corner where I mostly work and a kerosene space heater if it gets really cold! I work in this workshop full time all year round, no rest for the wicked! What engine is your 2.0 and what's up with it? A Zetec or an RS I4? Another update, Main Bearing Shells ready to fit - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0088.jpg Fitted to the block - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0089.jpg New Thrust washers/bearings ready to fit - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0090.jpg Fitted - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0091.jpg Crankshaft Cleaned up and fitted - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0092.jpg Main Bearing Caps fitted with new Bearing Shells and ready to fit - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0093.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0094.jpg Main Bearing Caps fitted and Torqued Down - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0095.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0096.jpg old Pistons and Rods ready for the Old Pistons to be removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0097.jpg Circlips removed which retain the Goodgeon Pin in the piston - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0098.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0099.jpg Using a piece of Alloy Bar as a Punch I knock the Goodgeon Pins out of the Pistons and Rods - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0100.jpg This allows the Rods to be removed - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0101.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0102.jpg New + 0.020" Oversize Pistons ready to fit - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0103.jpg Circlips fitted to one side of each piston - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0104.jpg http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0105.jpg Now this next bit is going to look a bit strange! I filled a small basin with Boiling Hot water and put the new pistons into it, when you do that the Piston expands with the heat and allows the Goodgeon pin to be slid in or out by hand - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0106.jpg I couldn't take photos of the pistons being fitted as there weren't enough free hands going around and you have to fit them quickly while the piston is still hot. Basically you remove the hot piston from the basin of water, slide the Goodgeon pin back, enter the conrod into the piston and slide the Goodgeon pin back through it and into the other side of the piston against the circlip I put in earlier - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0107.jpg All new Pistons fitted to the conrods - http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0108.jpg Link to comment Share on other sites More sharing options...
ganges Posted February 14, 2013 Share Posted February 14, 2013 the old tricks are the best, love the hot water trick , simple but effective, another cracking update Link to comment Share on other sites More sharing options...
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