Mk2 Cortina 1600E Crossflow Engine Reconditioning

[blacksofstichill]

Cheers, much appreciated!

I've just noticed it's changed all my spellings for G U D G E O N Pin to Goodgeon Pin instead, not sure why that happened becuase I do know how to spell it!

[ganges]

Cheers, much appreciated!

I've just noticed it's changed all my spellings for G U D G E O N Pin to Goodgeon Pin instead, not sure why that happened becuase I do know how to spell it!

 

 

but of course you do

[blacksofstichill]

Honestly! It seems to do it automatically on here for some reason, it must change G U D to GOOD. Not to worry!

 

New Big End Bearing Shell fitted to Conrod No 4 -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0109.jpg

 

Piston Rings Compressed and Piston entered into the bore -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0110.jpg

 

That's Piston No 4 fitted right down the bore -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0111.jpg

 

Conrod No 1 fitted with new Bearing Shell -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0112.jpg

 

Rings compressed and piston No 1 entered into the bore -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0113.jpg

 

That's Pistons 1 & 4 Both fitted and ready for the Big End Caps to be fitted -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0114.jpg

 

Big End Caps for Conrods 1 & 4 fitted with new Bearing Shells -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0115.jpg

 

Big End Caps fitted to 1 & 4 -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0116.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0117.jpg

 

That's 1 & 4 Done -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0118.jpg

 

No 2 Conrod fitted with a new Bearing Shell -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0119.jpg

 

Rings Compressed and No 2 Piston entered into the bore -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0120.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0121.jpg

 

No 3 Conrod fitted with new Bearing Shell -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0122.jpg

 

Rings Compressed and Piston 3 entered into the bore -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0123.jpg

 

That's No 2 & 3 Fitted into the bores -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0124.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0125.jpg

 

Conrod Caps for 2 & 3 fitted with new Bearing Shells -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0126.jpg

 

Caps Fitted to 2 & 3 -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0127.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0128.jpg

 

All 4 Pistons and Rods now fitted and Torqued up -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0129.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0130.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0131.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0132.jpg

[Ahmotorsport]

Bloody hell! That piston ring clamp is going back a bit! Good to see some old kit put to good use. Top work.

[blacksofstichill]

Cheers! Yeah, a lot of the kit I use is older than me!

[rs2k_mad]

Fantasic thread! Enjoying watching the progress. Have a huge soft spot for these as my father owns a immaculate gold 1600E. Great work!

[Ahmotorsport]

Cheers! Yeah, a lot of the kit I use is older than me!

Hear hear!

[blacksofstichill]

1513369[/url]']

Fantasic thread! Enjoying watching the progress. Have a huge soft spot for these as my father owns a immaculate gold 1600E. Great work!

Thanks, much appreciated! This engine is also out of a gold one and it's a minter too, I'll speak to the owner and if its okay with him I'll post some pics of the car up here.

 

 

1513371[/url]']

 

Hear hear!

[Naylor2006]

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?

 

Its a Zetec, if you get a spare year take a look at at my progress thread in my signature.

 

Nothing up with it as such, just an engine that could do with being rebuilt to restore the tolerances and such.

 

Nice updates!

[scottybo]

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?

 

Its a Zetec, if you get a spare year take a look at at my progress thread in my signature.

 

Nothing up with it as such, just an engine that could do with being rebuilt to restore the tolerances and such.

 

Nice updates!

 

if you skip the billion pages about dodgy idle naylors thread is quite a good read lol

[blacksofstichill]

1513417[/url]']

Its a Zetec, if you get a spare year take a look at at my progress thread in my signature.

 

Nothing up with it as such, just an engine that could do with being rebuilt to restore the tolerances and such.

 

Nice updates!

 

 

1513470[/url]']

 

if you skip the billion pages about dodgy idle naylors thread is quite a good read lol

Cheers, yeah, I had a quick look over the thread and it looks good, will take the time to have a proper read through of it all though. I remember seeing the car at ford fair looking very tidy indeed!

[blacksofstichill]

Timing Cover and Crank Oil Seal Housing as removed -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0133.jpg

 

Both cleaned up -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0134.jpg

 

Old Oil seals removed -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0135.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0136.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0137.jpg

 

Both Primed -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0138.jpg

 

Timing Cover painted in Gloss Black -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0139.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0140.jpg

 

Crank Seal Housing painted in Gloss Black, although this won't be see once it's fitted I decided it wouldn't do any harm to give it a quick coating -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0141.jpg

 

Next on the agenda is the Sump, here's how it stands just now, quite rusty and oily in bits -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0142.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0143.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0144.jpg

 

the sump took a bit of cleaning but I got it back to bare metal -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0145.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0146.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0147.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0148.jpg

 

Zinc Primed -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0149.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0150.jpg

 

While the paint was drying, Alex tried to hotwire my Dad's Van -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0151.jpg

 

And after 4 coats of gloss black -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0152.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0153.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0154.jpg

 

New Oil Seals ready to fit -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0155.jpg

 

And fitted -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0156.jpg

[sidrick]

Another sweet update

[Naylor2006]

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?

 

Its a Zetec, if you get a spare year take a look at at my progress thread in my signature.

 

Nothing up with it as such, just an engine that could do with being rebuilt to restore the tolerances and such.

 

Nice updates!

 

if you skip the billion pages about dodgy idle naylors thread is quite a good read lol

 

Joker lol

 

 

1513417[/url]']

Its a Zetec, if you get a spare year take a look at at my progress thread in my signature.

 

Nothing up with it as such, just an engine that could do with being rebuilt to restore the tolerances and such.

 

Nice updates!

 

 

1513470[/url]']

 

if you skip the billion pages about dodgy idle naylors thread is quite a good read lol

Cheers, yeah, I had a quick look over the thread and it looks good, will take the time to have a proper read through of it all though. I remember seeing the car at ford fair looking very tidy indeed!

 

Quite cool to have made an impression, tis what it's about sometimes.

 

Nice update man.

[blacksofstichill]

Thanks Lads, much appreciated!

 

Crank Pulley in need of a clean up -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0157.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0158.jpg

 

Cleaned back to bare metal -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0159.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0160.jpg

 

Primed -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0161.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0162.jpg

 

Painted in Gloss Black -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0163.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0164.jpg

 

Oil Pump before cleaning -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0165.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0166.jpg

 

End plate removed to check the condition of the pump -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0167.jpg

 

Old Gasket removed and mating face cleaned up -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0168.jpg

 

Pump Masked up ready for painting, it was already well cleaned of loose paint, etc before I got it so a quick degrease and rub down was all that was required -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0169.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0170.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0171.jpg

 

Primed -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0172.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0173.jpg

 

With the paint drying on the Oil Pump, it was time to fit the Cam Followers. I'd previously been supplied the wrong ones, this engine being an early one it has narrow stem followers rather than the later wide stem ones. Luckily I was able to source a New Old Stock set from a local supplier -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0174.jpg

 

Fitted into the block -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0175.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0176.jpg

 

New Camshaft being fitted -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0177.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0178.jpg

 

Alex giving it the final push into the block -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0179.jpg

 

And it's finally fitted right home -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0180.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0181.jpg

 

Camshaft Retaining Plate fitted -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0182.jpg

 

Back to the Oil Pump for a coat of Gloss Black -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0183.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0184.jpg