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Old 05-14-2013, 08:29 PM   #16
tempfixit
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Re: 94 Ford Escort 1.9L Engine Rebuild Issue

Have you double checked to make sure you did not mistakenly install a rod bearing cap backwards ???? Just a thought.
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Old 05-14-2013, 08:33 PM   #17
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Re: 94 Ford Escort 1.9L Engine Rebuild Issue

The new crank bearings are exactly the right size: 0.083"

So I compared them to the old crank bearings.

The old crank bearings are worn down to 0.081" in some fairly large areas.
That's 0.002" difference between the two in some places!


I'm assuming that the crank is the issue. I'll trying re-installing the old bearings tomorrow and see if it solves the issue.

Last edited by hakachukai; 05-15-2013 at 01:05 AM.
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Old 05-14-2013, 08:35 PM   #18
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Re: 94 Ford Escort 1.9L Engine Rebuild Issue

Quote:
Originally Posted by tempfixit View Post
Have you double checked to make sure you did not mistakenly install a rod bearing cap backwards ???? Just a thought.
Yes I did check all of that type of thing.

In this engine it's not possible. If you install them facing the wrong way they won't properly mount at all. It's very obvious if you get one wrong.
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Old 05-15-2013, 09:59 AM   #19
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Re: 94 Ford Escort 1.9L Engine Rebuild Issue

When I do a deep rebuild, I always pass the crank through a engine specialty shop. Just to have another set of eyes checking all the surfaces. They always mount the crank in a lathe and give it a "polishing", even if it requires no futher reginding. I figure this is to justify the $50 min service charge ... but it may do some good.
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Old 05-15-2013, 08:46 PM   #20
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Re: 94 Ford Escort 1.9L Engine Rebuild Issue

They may have to do that or similar just to check the balancing.

Pain in the ass procedure but, is it possible to try and isolate the problem to a specific cylinder by installing one rod/piston at a time between manual cranks ?
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Old 05-16-2013, 01:53 AM   #21
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Red face Re: 94 Ford Escort 1.9L Engine Rebuild Issue

Update on this engine:

I tore it back down to bare bones and started over. This time instead of just re-assembling the whole thing I did it one piece at a time and tested each one.

I think I must have made a mistake somewhere last time, because this time the results are good.

Currently I have all 5 crank bearing caps installed and torqued down ( with the new bearings ). The crank turns over with no problem!

Tomorrow, after some rest... I'll torque down the connecting rod bearings one at a time.
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Old 05-16-2013, 03:25 AM   #22
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Angry Re: 94 Ford Escort 1.9L Engine Rebuild Issue

ok, so I also torqued down the connecting rod bearings.

I verified that the pistons are installed in the correct order ( the cylinder numbers are stamped on the connecting rods and the connecting rod caps ).

I also verified that none of the connecting rod caps are installed backward.

Piston #1 and #4 function fine.

All pistons have no trouble sliding in the cylinder.

When I torque down the connecting rod cap on #3 it locks the engine.

When I torque down the connecting rod cap on #2 the engine is difficult to turn.

Further investigation tomorrow.
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Old 05-17-2013, 03:30 AM   #23
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Angry Re: 94 Ford Escort 1.9L Engine Rebuild Issue

Piston #3 still locks up with I torque the connecting rod nuts.

I've been carefully looking it over and noticed a few things:

I measured the clearance using plastigauge ( placed in the bottom center of the connecting rod cap ). The clearance is within spec. It's 0.0015 on one side and about 0.0017 on the other side.

I noticed that the upper connecting rob bearing is a little bit too long. Even when it is seated properly, the tip of it sticks out past the upper connecting rod edge by about 1/1000th " ( none of the other connecting rods did this )

I also noticed that the connecting rod cap is staggered away from the timing belt side. I didn't measure the exact amount, but it is noticeable. I'd say somewhere between 1 and 3/1000's "

With the connecting rod cap nuts un-torqued it moves fine.

I removed the lower connecting rod bearing and torqued the nuts. It turned fine ( this was a test to check for side binding of the cap )

I re-install the cap and bearing ( which is now perfectly aligned with the upper bearing )... it locks the crank shaft every time!



So... I painted the lower connecting rod cap on all sides with a black dry erase marker.
Re-installed it at 10ft-lbs ( normal is 30ftlbs ).
It was hard to turn, but I turned the engine over several times and removed it.

The marker was completely scrubbed off on one side of the cap ( the side away from the timing belt [ which is the same direction that it's staggered in] ).

A good bit of the marker was scrubbed off in the lower bearing.

The marker on the timing belt side was completely untouched.

I posted pics to show what I'm talking about
Attached Images
File Type: jpg IMG_20130517_032636.jpg (146.9 KB, 4 views)
File Type: jpg IMG_20130517_032712.jpg (150.6 KB, 4 views)
File Type: jpg IMG_20130517_032814.jpg (147.9 KB, 4 views)
File Type: jpg IMG_20130517_033433.jpg (138.5 KB, 4 views)
File Type: jpg IMG_20130517_033450.jpg (148.3 KB, 4 views)
File Type: jpg IMG_20130517_033501.jpg (155.5 KB, 4 views)
File Type: jpg IMG_20130517_033836.jpg (207.6 KB, 4 views)
File Type: jpg IMG_20130517_034039.jpg (139.3 KB, 4 views)
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Old 05-17-2013, 04:50 AM   #24
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Re: 94 Ford Escort 1.9L Engine Rebuild Issue

Have you tried assembling cap-to-rod, without bearings, just to see if the cap straightens?

That rod and cap seem to be quite weathered. I would pass all of them thru a shop that reconditions rods ... since you don't know the history of the engine, there may be a mismatch (cap and rod) ... or prior damage.

You are doing good work, I think.
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Old 05-17-2013, 10:09 AM   #25
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Re: 94 Ford Escort 1.9L Engine Rebuild Issue

Does the cap and rod have any b;ueish appearance to them, I second 12Ounces suggestion and I would also have the crankxhaft rod journals checked also.
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Old 05-17-2013, 02:53 PM   #26
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Re: 94 Ford Escort 1.9L Engine Rebuild Issue

Nope, no bluing has occurred. I don't see any signs of heating or serious wear anywhere.

Just worn out bearings, and some minor wear on the crank journals that is slightly out of spec, but even.

I think this engine should be usable the way that it is, I just have to figure out what is causing this issue. I'll do some more checking with feeler gauges. I'll also try it using the old bearings and see if that makes a difference.
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Old 05-21-2013, 11:13 PM   #27
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Re: 94 Ford Escort 1.9L Engine Rebuild Issue

Just for the sake of verification... which direction is the correct direction to install these connecting rod caps?

Are the bearing notches supposed to touch each other, or are they supposed to be on opposite sides?

The connecting rod and the caps also have cylinder numbers stamped on them.
Are the stamped numbers supposed to be on the same, or opposite sides?

Last edited by hakachukai; 05-22-2013 at 01:00 AM.
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Old 05-22-2013, 01:40 AM   #28
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Red face Re: 94 Ford Escort 1.9L Engine Rebuild Issue

Update:

Ok, So I tried flipping the connecting rod caps around.

Now the bearing notches are both on the same side, but they do not touch. One is on the right side and the other is on the left side.

Also the stamped numbers on both the connecting rod and the connecting rod cap line up ( they are on the same side ).

I did this to all 4 cylinders and it turns over free and easy. The side clearance looks good too.

I just want to double check that this is correct before I re-install and run the engine. That last thing that I want to do at this point is spin a bearing!
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Old 05-22-2013, 04:45 AM   #29
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Re: 94 Ford Escort 1.9L Engine Rebuild Issue

Yes, the caps and rods are punched on the same side. If you did not pay attention to this earlier, that would certainly cause a lock-up ... as the cap and rod are first assembled, then punched, then bored .... then separated again during manufacture. If later assembled with cap backwards, the bore of the cap won't match the bore of the rod ... and will be slightly offset. This also answers why the cap seemed to be inclined to the rod ... it was backwards.
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Old 05-22-2013, 04:50 AM   #30
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Re: 94 Ford Escort 1.9L Engine Rebuild Issue

BTW, if you have removed the pistons and rods from the block ... you must make sure the rods are oriented correctly also. There is a arrow head mark on the piston top that must face the front of the engine.
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