The day had finally come to put the heart back into the RS2000. Straight after work, it was time to get the engine bay detailed and ready for its new engine. The only thign I don't like about the engine bay are the old faded yellowed plastic window washer and brake fluid bottles and hoses. May have to source new ones of those from somewhere, or make some new ones up.


The engine on the crane, about to be unbolted from its home for the last few months. I left the rocker cover off to avoid damage in the installation.



The first step after getting the engine onto the stand was to get the rear main seal on. We worked the seal on about two thirds of the way before it wouldn't go on any further by hand (sore sore thumbs doing this!), but we didn't have any way of being able to tap it in further. So a quick hunt around the garage found the ring compressor for the pistons, shaped to the right size, wrapped and taped with rag to ensure it didn't damage the seal, ready to do the job. After a few nervous taps, it seated into place ok, job done.



The flywheel, having been machined, was installed easily, and torqued to the appropriate value. Time to put the clutch on, and the clutch alignment tool was worth every cent of the ten dollars it cost. Slid the friction plate onto the alignment tool, slid it into the crankshaft, and then the pressure plate got bolted on over the top. Alignment tool gets pulled out, job done, no clutch alignment worries!



Some car shuffling had to take place to get the RS to where the engine was. Fortunately in our new house we will have three garage so each Escort will have its own home. On a side note, I absolutely cannot stand the wheels on the RS which will be replaced when money permits.



The gearbox slid straight onto the engine easily, and bolted up accordingly.



Everything together, and time to get her into place. Some minor positioning and the engine / gearbox combo slid straight in, no worries what'soever.



Engine in place! The chrome rocker cover was temp installed in place to protect the engine until I have finished painting up the deep blue one for this car. A couple of minor things to go in the engine bay, like re-spraying the steering column shaft, battery tray, and replacing those old yellow bottles, but with a fresh worked engine in the bay, the car should still drive a treat!



I am moving house over the next few weeks so I won't be able to work on the Escorts for five hours every night like I have been, but I won't be stopping! Absolutely cannot wait to get this engine fired up!

Timmeh!

Coming along very nicely. Should look a treat when she's all bolted up. If I'd known mine was going to take this long, I would of had the engine bay detailed and all the holes welded up. I guess that's the real benefit with doing the work yourself as you know the time frame 100%.

Yeah, it does take time. It just depends how many other commitments you have as well, like family, and how much money you have to throw at it. Because even though I did the engine work myself, consumables like gaskets kits still cost money, and specialist tool jobs like machining the flywheel / honing the cylinder bores still cost money also.

Also a variety of things needed replacing along the way, things like thermostats / housings, water pump, piston rings, etc.

I should do a total breakdown cost on the engine rebuild and post it.

Timmeh

Thanks Marty - yeah I have been told by other friends not to as well, haha, but it's tempting just to see!

Tim

Feels like forever since I have posted in this thread!

Since last time, I have:

Installed the extractors.
Installed the alternator, water pump, fan belt, and fan.
Installed the radiator, thermostat housing, and thermostat.
Installed the starter motor, ballast resistor, and engine earthing lead.
Installed the inlet manifold with the 40DFAV Weber and attached the accelerator cable and tensioned appropriately.
Removed the timing belt, scrubbed all the damned rust that had formed on my camshaft pulley and tensioner, painted it in the same charcoal engine block colour, and refitted the timing belt. Was told they had been treated so they wouldn't rust - bollocks!


Don't want any of that rust stuff in my RS2000, least of all straight after a total rebuild! Good riddance.



Finished spraying the new rocker cover in Royal Blue and clear coated it when that was finished. The chrome one on the engine is purely to keep dust / foreign objects from getting into the head during the moving of the car from the old house to the new house.



The car should be ready to start in a day or two, just need to locate where I put the cars brand spanking new ignition leads and plugs during the move! Moving house halfway thru a car project or two sucks!

Well, today the rain left me alone once more and I had enough of working on the rally car's rollcage, so it was back to the RS2000.

Finally got to put the Royal Blue rocker cover that I restored on (that cork gasket is a real smeghead until you work out the trick getting it on), and also put the battery in and the air cleaner on. I gave the engine a once over to check everything.



I still haven't found the brand new set of ignition leads or plugs since I have moved house, so if I don't find them in the next day or two I'll go out and buy a new set. I need to attach all the ignition leads and coil, put on the oil pressure sender, reattach the clutch cable, check coolant and oil levels, and give her a good kick in the guts!

The engine has gone from this:



To this:



And finally to this:



Pretty happy with how she looks. It's the stronger German block, and the whole setup will still be good for a low pressure turbo or supercharger later if I feel the need for speed, as that was the initial plan before I decided to buy the rally car. I need to rub down and respray those brakes lines though, surface rust is the devil! A new washer bottle wouldn't hurt either.

So... I need to find those silly ignition leads! Boy I can't wait to start it, and I am sure my neighbours will love it too, with no exhaust on past the extractors yet.

Timmeh!

Engine looks great. The colour of the rocker cover really works well, especially in a white car

Looks great Timmeh... hope to see it on the roads very shortly

Since last post, I have:

Filled the manual transmission with oil
Fitted the tailshaft
Fitted the clutch cable and adjusted it accordingly
Installed the coil, plugs, and leads
Installed all the coolant hoses
Filled with coolant
Put a couple of shot glasses of fuel into the carby, and:
Turned the key.
And bugger me - it actually runs!

Of course, there were a few hiccups. The starter motor originally did not want to turn. The carby wanted another shot glass of alcohol. The extractors smoked like a mad ba$tard as the oil that was spilled on them burnt off. And finally, I proved why you should never stand over a Weber with a nice healthy backfire. Fortunately I videoed the start for my own interest, so first a couple of still images as I edit the video of the RS2000 running for the first time! With no extractors, its pretty loud and had very low back pressure of course.

Beware: Backfire In Progress!


Up the bonnet it travels.



Video to come!

[:x)]

How exciting. Timmeh!

Well, here is a little video put together of the starting ordeal. I was suprised that it started over first turn of the key, let's hope it always does.

First in the video I just wanted to turn it over by starter to check the engine, then I install all the leads and fire it up. And of course, a nice big backfire at the end.

It's 1.8MB, right click the link and choose Save As or Save Target As and enjoy!
Video Link Here

Now it is onto touching up all the small things, such as installing the heater I restored and interior trim, getting the rest of the exhaust installed, and tuning the engine on the dyno. Hopefully many more videos to come, with wheels turning and full throttle applied (once run in, of course!).

Timmeh

Lucky no one else was around or they'd lost their eyebrows...hehe

Great vid though