Duratec 2.0 advice/help!

[DarrenAshley]

Hi all,

Excuse my inexperience here, but I am in need of some help. I imported a C400 to Australia from the UK, and I have been let down badly by the sellers (A well known UK race team). Having got the car here and had it assessed by a local engine builder, it needs a full rebuild.

When the engine shop took the oil filter off and inspected it, look what was found!

This all came from the scavenge pump:

We stripped the engine down and found various other issues:

1. Rust on exhaust valves



2. Moisture in bores



3. Conrod bolts not correctly tensioned (Only had around .002” stretch)
4. Crank shaft end float excessive – 0.014”
5. Piston to bore clearance excessive – 0.0055”

The cylinder head has been pressure tested, it is OK. How the water got it we do not know.

My questions are related to getting this car back on track:

1. The pistons are already 88mm. What is the best way forward here? The engine shop are talking about boring the cylinder and getting pistons made, or getting a new block, however they are not working on Duratecs regularly here in Australia. New custom pistons seems very complicated. Could we hone the block and use the existing pistons? The UK race team who sold this to me said there was no excessive clearance when it left the UK, the bores don’t grow at sea so what is everyone’s thoughts on those clearances of 0.0055”? Could it just be honed (Depending upon the condition), or are those clearances too large already? Should I look at a new block, and get it bored to fit the existing pistons? If so, any recommendations on suppliers? I have seen Raceline advertise them.
2. The Caterham dry sump fitted seems from what I have read to have had issues and is no longer in regular supply. It seems you cannot get the scavenge pump in isolation, and have to get the kit, and the new pump that comes with it is oil and scavenge pump? Anyone know if you can get just the old scavenge pump? Part number is YR0232/03. I cant find it anywhere. If not, I will just get the Raceline kit and be done with it

The cylinder head will be cleaned up, the valves too and a rebuild will be done, I just need to get over this hump with the dry sump/pump and the block/pistons.

Any recommendations on suppliers too would be good. I have reached out to SBD and got pricing for bearings etc, and will speak to Raceline on the dry sump kit.

Thanks all!

[David_Long]

As posted on the PH forum, but this looks like what you might expect from a race car of the C400 era. The water is probably from storing the car in the rain. How was it shipped to you? In a container? Any induction/engine prep for a sea journey?  Clearances can be larger than OEM on race pistons and this does not sound too excessive to me, but checking the piston make with their spec will give you a better idea. It could be salvageable but it may be more cost effective to start with a better 'donor' engine.  I'd avoid re-boring as this generation of engine does not respond well to that and best avoided (at least in my experience). If budget allows, a new crate engine, or the newer 2.5L engine for budget fun.

[DarrenAshley]

Thanks David. I posted in PH whilst I waited for my membership here.

Really appreciate the advice. Donor engine does sound the way to go from what I am being told...

[7 wonders of the world]

As above measure everything and if the bores can be honed thats fine 88mm pistons in various forms are available from Supertech who have an agent in Oz or US ones will ship, rods, bearings again easy to come by, 

Peter @ Raceline will sort all you need in a big box I'm sure.

This does open up the opportunity to unleash a few more ponies too, 

 

Sea containers are a nightmare in previous roles we lost several 40' containers of bikes through poorly sealing doors. 

 

[DarrenAshley]

Thanks, appreciate it too. I spoke to Raceline, and I am just waiting on their response. 

Not really thought about adding more power, but I should! Every cloud... :)