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Thread: 2.0L Duratec Rebuild

  1. #91
    Join Date
    Jan 2006
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    Seattle-ish
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    Nah, I had to stop doing that a couple of months ago. Given the frequency, my doctors feared I was at risk of developing CTE. These days, I just scream obscenities at the top of my lungs followed by very heavy drinking. In fact, I'm having a big ass martini right now.

    -John
    '95 Westfield SEiW w/2.0L Duratec
    '68 Lotus Elan FHC
    '91 Miata w/Flyin Miata suspension & brakes
    '95 Porsche 993 C2
    '86 Porsche 944 turbo (neglected project car)
    Throttle Steer

  2. #92
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    Thanks to prompting from another forum member, I may have had a breakthrough on the O-ring issue. He asked if it was possible the old O-ring was really two stacked O-rings that created a virtual oval. Although certain that wasn't the case, thinking about it, I vaguely remembered the O-rings were pretty distorted, so out to the garage for another look.

    One O-ring was pretty flattened, but the other was more wedding ring shaped and upon closer examination appeared to have tiny numbers molded into the side. These weren't legible with the naked eye -- or at least not mine -- but a USB microscope shows 1S7G 6625 AB. Closest I can find online is 1S7G 6625 AA, which differs only in the last letter. Apparently that simply designates the version number. Fingers crossed it's the right part and arrives in a reasonable timeframe.

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    -John

    .
    '95 Westfield SEiW w/2.0L Duratec
    '68 Lotus Elan FHC
    '91 Miata w/Flyin Miata suspension & brakes
    '95 Porsche 993 C2
    '86 Porsche 944 turbo (neglected project car)
    Throttle Steer

  3. #93
    Join Date
    Oct 2006
    Location
    Cincinnati
    Posts
    3,693

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    I am starting to think that brain surgery would be simpler than a Duratec rebuild!
    Kitcat:AKA, Sir Spinsalot
    '97 Caterham Super Sprint, 1700 Crossflow-sold
    '09 Birkin S3, Duratec-sold
    '03 Caterham Zetec track car
    '19 Honda Type R, sold
    '19 Miata Clubsport

  4. #94
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    Good point. In the future, when pointing out that something isn't that difficult, rather than say "It isn't brain surgery" we can say "It isn't rebuilding a Duratec."

    -John
    '95 Westfield SEiW w/2.0L Duratec
    '68 Lotus Elan FHC
    '91 Miata w/Flyin Miata suspension & brakes
    '95 Porsche 993 C2
    '86 Porsche 944 turbo (neglected project car)
    Throttle Steer

  5. #95
    Join Date
    Feb 2009
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    NYC
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    I am more impressed with John's calm, patient, philosophic acceptance of what has to be incredibly frustrating hiccups. This thread will be a valuable resource to rebuilders of early adoption Duratecs in the future. Mind you I suspect John has also improved his beer consumption being locked down with a Duratec.
    Mike
    2010 Caterham CSR with Cosworth 2.3 Duratec
    2018 Caterham 420R with 2L Duratec 210hp at Donington UK
    1975 BMW CSL Group 4 (restoration - engine and dry sump install time)
    1977 Holden Torana "A9X" (awaiting restoration)
    1985 Holden Commodore SS Group A
    1985 Holden Commodore Group A
    1982 Ferrari 400i
    1965 Ford Mustang Fastback "Holman Moody"
    1992 Ford Escort RS Cosworth WRC (fettling after long period of storage)
    1990 Range Rover 2 door Classic
    and another project car coming....

  6. #96
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    The part arrived and I just did a test fit; we have a match! Hopefully I can spend some time in the garage this weekend assembling the engine. Which reminds me, has anyone started a pool yet on when I discover the next blocker to that process?

    -John
    '95 Westfield SEiW w/2.0L Duratec
    '68 Lotus Elan FHC
    '91 Miata w/Flyin Miata suspension & brakes
    '95 Porsche 993 C2
    '86 Porsche 944 turbo (neglected project car)
    Throttle Steer

  7. #97
    Join Date
    Dec 2014
    Location
    Los Angeles
    Posts
    255

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    I have the older Raceline wetsump. The fellow I acquired it from had converted to the Raceline dry simp stop om his 2.0l Duratec. I contacted Raceline and the sent me an"update" kit so that the older wet-sump would work with my 2.3l Duratec. I recall the wedge and the o-rings. I considered the higher output oil pump but stayed with a new stock one. There is no really valid way to measure the internal clearances in the oil pump but by installing a new one, you are pretty much assured of decent oil pressure. I run 0W40 Mobil One and see 85-90 psi cold and 20 psi at a hot idle.

    If Peter can't find the proper o-ring, he should send you a correctly machined wedge. I just had some parts sent over from England. One week via Royal Mail, 3 days via DHL currently.

  8. #98
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    Thanks, but I'm set. The o-ring (actually a gasket) arrived and is the correct part. I'm curious about your update kit comment. Are you referring to the oil pump/oil pickup interface, or do you mean a balance shaft delete kit for the 2.3L? My wedge was machined correctly, it's just that they changed the design after the first dozen sumps and that gasket was no longer used. To convert to the new one would require machining the sump as well to allow the thimble assembly to fit.

    Thanks,
    John
    '95 Westfield SEiW w/2.0L Duratec
    '68 Lotus Elan FHC
    '91 Miata w/Flyin Miata suspension & brakes
    '95 Porsche 993 C2
    '86 Porsche 944 turbo (neglected project car)
    Throttle Steer

  9. #99
    Join Date
    Dec 2014
    Location
    Los Angeles
    Posts
    255

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    As I recall, the kit included the wedge and a new windage cover, several o-rings and a short section of pipe. A couple of the rings were square cross-section, if I remember correctly, to fit the grooves in the wedge. Haven’t had it apart since. It would have been nice to get a new tubular screen for the return filter. Have fun!

  10. #100
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    Interesting. I wonder if there are more than two versions? According to Peter, the wedge without an o-ring groove on the sump side has to be used with the thimble assembly, and that requires the top of the port to be opened up from 16mm to 24mm. If you didn't have to do that machining and you are using the thimble, then there must have been an interim version. The photos below were taken from the most current installation instructions and show the assembled thimble, port with larger top section (have to look hard to see the step), and the thimble in place.

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    Name:  Raceline port 2.JPG
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    -John
    '95 Westfield SEiW w/2.0L Duratec
    '68 Lotus Elan FHC
    '91 Miata w/Flyin Miata suspension & brakes
    '95 Porsche 993 C2
    '86 Porsche 944 turbo (neglected project car)
    Throttle Steer

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