Ford Escort rebuild journal

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Ford Escort Documentary

Documentary for Ford Escort rebuild and preformance report

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-Problem- Engine run at high rpm's after repair of previous engine failure (bad vacuum, bad electrical, blown head gasket, internal coolant leaks) High rpm caused many problems as a result of a problem, wore out brakes very fast and broke a piston. It was fun to drive with the increase of horsepower....

-Solution 1- The broken piston badly scored the number 4 cylinder. I then attempted to hone out the scores in the cylinder and install a oversized piston/rings to fit the cylinder. I managed to overbore the cylinder and got rid of all the scores except one which caused me to bore a hole in the cylinder bringing my plans to a stop... I then panicked and jumped on the phone to find a sleeve to stuff in there (thinking no one will know I just want to drive the car). My suggestion was to just get a new engine, really stressing on getting a new car. >>No! I'm a mechanic I can get it running somehow!<< I went to the "Lucky Junkyard" and managed to get an engine at a very good price. After getting it home, I then disassembled it completely.

-Solution 2- I machined the used engine block (be sure to check if the block has been overheated or any other serious problems before buying or installing this could ruin the idling process!). Hone and machine to the correct measurements, I installed the crankshaft and fly wheel to the block and attached the torque converter to the transaxlel to prepare for mounting the block. I did not remove the transaxlel and no use of a hoist which made the installation very difficult... but I was able to get the bolts line up and mounted the block correctly. Then installed bearings, pistons, water pump, oil pan, starter, and head gasket to prepare for 1st no start run to allow the oil to circulate the block.

-Test 1- I then connected the required components to attempt to start the vehicle (make sure all electrical connections are properly connected, replace old wires as necessary). The engine gave me problems to start it up, so I preformed the ignition tests:

-Charged the battery

-Checked for spark at ignition coil

-Checked for spark at distributor

-Checked for proper fuel injection

-Check for air intake -checked compression

-Check engine timing

I had to double check for spark because everything check out fine even after a computer diagnosis. I removed the new ignition coil and installed the old coil to check for spark... I discovered I had spark... I next checked for distributor spark, and here's what I came up with. It happens to me every time, I held the wire by the installation gapped to a ground and started the car... it sparked like crazy, so I went to pull my had away it kept sparking... shocked the heck out of me and then the car started... aaaggghhhh!!!! So now it runs like a dream after a nightmare

I encountered some bugs during normal driving conditions. In order to qualify for the E-check, I needed to replace the connecting rod bearings that caused a knocking problem, also the valve in the throttle body needed to be bent in to the correct position which was causing to much air into the cylinders resulting in high rpm's there is also a surging problem, I needed to correct the electrical timing. These adjustments will improve the horsepower the 1.9 engine will put out. I have recorded the vehicles operating performance...