RayC333 Posted May 3 Share Posted May 3 Well, as some of you may remember back in late 21/early 22, I undertook a big engine job on what was then my daughters car. A 2012 Ford Focus 1.0 Ecoboom. (engine out, stripped pretty much completely, flushed and cleaned, replacement crankshaft, conrod and all bottom end bearings. New vacuum pump, turbocharger, oil pump, belts, gaskets, etc), Surprisingly the car went fine for a few months, albeit with a bit more head scratching over a split turbo vacuum pipe, until the car started to be come unreliable again - intermittent starting problems, needing coolant top-ups, but despite that running fine without any problems once started. In the end, it was too problematic having three children to get to school etc. so, with a little help from family members, she now has a different (reliable) car. A Honda HRV. Anyway, I got the car back to my place and have just recently started to diagnose the problem and have begun to strip the top end - yes, I am a glutton for punishment! Symptoms: 1. Progressively worse starting. Replaced the crankshaft position sensor some weeks ago (as previously has similar symptoms on a different car) and fitted new spark plugs - made little difference. 2. When fitting the new spark plugs, noticed the originals seemed to be oily/wet. With dry plugs in the car would start and run fine. Curious as the engine is not overheating, no white smoke or showing any bubbles in the expansion tank. 3. Starting problems getting worse. Took the spark plugs out one morning after a 20 mile journey the previous day, spun over the engine and water (coolant) shot out of all three cylinders! 4. Suspected the head gasket, but I wouldn't normally anticipate leakage into all three cylinders and no other common symptoms. 5. Today I removed the studs holding the Turbo to the Cylinder Head and was maybe not so surprised to see coolant coming out of the Exhaust Manifold (integral with the head on these engines). The car isn't needed now, is in my name, so I'll press on slowly out of interest to see what's happened. My bet is on a cracked cylinder head (not uncommon I'm told). Any club members think otherwise? 2 Quote Link to comment Share on other sites More sharing options...
unofix Posted May 3 Share Posted May 3 1 hour ago, RayC333 said: yes, I am a glutton for punishment! You need psychiatric help urgently !!! 🤣🤣 I warned you way back when, that it was a lost cause to try and save a 1.0 Ecoboom. Still I admire your determination (but still think you're crackers 🙄). My diagnoses is cracked cylinder liner(s) near the cylinder head caused by overheating. repeated expansion and contraction of the liners eventually leading to failure. I look forward to the weekly updates as the autopsy progresses. 👍 4 Quote Link to comment Share on other sites More sharing options...
Eric Bloodaxe Posted May 3 Share Posted May 3 I'd go with cracked head (the car, not yours) also. Gotta admire your persistence! 1 Quote Link to comment Share on other sites More sharing options...
Jimpster Posted May 3 Share Posted May 3 silly question is it wet linered ? had a 206 with unfathomable issues till the piston liner went thru the top of the engine. 1 Quote Link to comment Share on other sites More sharing options...
TomsFocus Posted May 3 Share Posted May 3 Definitely need your head examined! 😉 2 Quote Link to comment Share on other sites More sharing options...
JW1982 Posted May 3 Share Posted May 3 17 minutes ago, Jimpster said: silly question is it wet linered ? had a 206 with unfathomable issues till the piston liner went thru the top of the engine. The 1.0 ECOboost has no liners at all. It has a cast iron engine block. The cylinders are machined (bored and honed) into the cast iron. The bottom end is basically quite strong. 3 Quote Link to comment Share on other sites More sharing options...
RayC333 Posted May 3 Author Share Posted May 3 2 hours ago, Jimpster said: silly question is it wet linered ? had a 206 with unfathomable issues till the piston liner went thru the top of the engine. No, no liners on this engine. 2 Quote Link to comment Share on other sites More sharing options...
RayC333 Posted May 3 Author Share Posted May 3 Coolant was sloshing around nicely in the cylinders today. No.1 was filled up so much it overflowed the plug hole when I turned the engine to TDC. Pistons, rings and bores must be ok to seal like that 😁 1 Quote Link to comment Share on other sites More sharing options...
RayC333 Posted May 3 Author Share Posted May 3 1 hour ago, JW1982 said: The bottom end is basically quite strong. Bottom end is great until it gets starved of engine oil 1 Quote Link to comment Share on other sites More sharing options...
RayC333 Posted May 6 Author Share Posted May 6 I now have the cylinder head off. Scratching my head at the moment as expected to find an obvious cause of failure but haven't. Bearing in mind coolant was freely getting into the cylinders, even when cold, I thought a couple of simple static water leak tests would suffice. Not so. The block and head faces look ok visually to me as does the head gasket. What I did find that shocked me is that some coolant passages were blocked or choked with some strange substance. This almost certainly caused local overheating in the cylinder head. I believe the material is from Holt's Radweld which I put in last year to stop a minor radiator leak. Have taken some photos. Options/ideas appreciated. The last photo is what Found in the expansion tank! Currently waiting delivery of an engineers straight edge to check the mating faces for distortion. Quote Link to comment Share on other sites More sharing options...
Jimpster Posted May 6 Share Posted May 6 If you intend going the whole hog i'd clean out all the routes and skim it anyway. 1 Quote Link to comment Share on other sites More sharing options...
unofix Posted May 6 Share Posted May 6 I know you're not going to listen because you're having too much fun, but it is time to call in a priest and give the poor engine the last rites. In the words of Scotty "she just can't take anymore more captain" 🤣 2 Quote Link to comment Share on other sites More sharing options...
TomsFocus Posted May 6 Share Posted May 6 1 hour ago, RayC333 said: What I did find that shocked me is that some coolant passages were blocked or choked with some strange substance. This almost certainly caused local overheating in the cylinder head. I believe the material is from Holt's Radweld which I put in last year to stop a minor radiator leak. This is exactly why I never recommend radweld or similar nowadays. It forms solids when in contact with air. If you don't bleed the cooling system perfectly (virtually impossible without vacuum filling) you will end up with air bubbles in the system where the radweld will create solids and block the waterways. 3 Quote Link to comment Share on other sites More sharing options...
RayC333 Posted May 13 Author Share Posted May 13 A short update: Head required re-surfacing to remove minor distortions, pitting and material deformation around the cylinder areas (caused by head gasket cylinder seals). Took hours and some expletives getting all the sealer debris out of the numerous coolant passages (debris only found on the exhaust side). Took the opportunity to remove all the valves, check and lightly lap the sealing faces, clean the ports and fit new new valve stem seals. Although not checked professionally, I couldn't find any sign of a crack in the head or block so fingers crossed. Currently waiting on parts, 4 Quote Link to comment Share on other sites More sharing options...
RayC333 Posted May 21 Author Share Posted May 21 Probably the end of the road. No sign of leakage after re-assembly a couple of days ago, but re-checked again today prior to completing the job and found that a small amount of water has got into all three cylinders again. The crack must be the typical one between the head coolant channel and the integrated exhaust manifold. Ford are aware of the problem but that's no consolation and of course don't want to know. All my hard work and hopes come to nought - gutted. Should have gone with Unofixes advice in the first place but just had to try before throwing in the towel 😞 2 Quote Link to comment Share on other sites More sharing options...
unofix Posted May 21 Share Posted May 21 3 hours ago, RayC333 said: Should have gone with Unofixes advice in the first place but just had to try before throwing in the towel I won't say it, as I'm sure you're already feeling down. 😞 You have won my admiration for sheer dogged hard work. It may be of help to others in the future who think they can save an Ecoboom with a spanner and a few parts form the local parts shop. I'm sure that it has been a learning experience and much of what you have discovered will be of great use on future projects. 👍 3 1 Quote Link to comment Share on other sites More sharing options...
RayC333 Posted Friday at 06:28 PM Author Share Posted Friday at 06:28 PM So, it irked me that my prep for leaks didn't find a crack or other problem before I re-fitted the cylinder head. Out of interest I thought I'd try and find out why. I found that the static water leak test I previously dreamed up was and is far too slow to notice a leak into a much larger coolant passage volume. I can now see a slight drop in water volume after waiting 24hrs but even then it's not as conclusive as I would like. Using bits and pieces from around my home I have now rigged up a better test, albeit still Heath Robinson. Nevertheless, take a look at the pics and video I've just taken with a bit of mains water pressure. Took a while to decide whether to post here or in Have a Laugh 😁 4 1 2 Quote Link to comment Share on other sites More sharing options...
unofix Posted Friday at 10:20 PM Share Posted Friday at 10:20 PM 3 hours ago, RayC333 said: Out of interest I thought I'd try and find out why. Do you not have a television in your house ? 🤣🤣 Ray you never cease to amaze me with your involvement with the 1.0 Ecoboom. I love the test rig and surprised at how apparently easily the water is leaking. So now you just need to work out how to repair the crack. Maybe you could get a guest appearance on Car SOS 👍 3 Quote Link to comment Share on other sites More sharing options...
tomo2001 Posted Friday at 10:35 PM Share Posted Friday at 10:35 PM Hope that's not your toothbrush? 4 Quote Link to comment Share on other sites More sharing options...
Jimpster Posted yesterday at 07:11 AM Share Posted yesterday at 07:11 AM Makes you wonder if Ford EVER went to this trouble or just said s0d it. 2 Quote Link to comment Share on other sites More sharing options...
TomsFocus Posted yesterday at 09:10 AM Share Posted yesterday at 09:10 AM 10 hours ago, tomo2001 said: Hope that's not your toothbrush? It's his wife's. She told him no more car parts in the kitchen sink! 😮 4 Quote Link to comment Share on other sites More sharing options...
RayC333 Posted yesterday at 11:48 AM Author Share Posted yesterday at 11:48 AM 13 hours ago, unofix said: Do you not have a television in your house ? 🤣🤣 now you just need to work out how to repair the crack. Funny you say that, I indeed do not have a TV 😀 A repair is technically possible with the right machining facilities, advanced welding and metal addition techniques, heat treatment, NDT etc but unfortunately it's a little expensive and wouldn't fit in my flat 😁 1 2 Quote Link to comment Share on other sites More sharing options...
RayC333 Posted yesterday at 11:50 AM Author Share Posted yesterday at 11:50 AM 2 hours ago, TomsFocus said: It's his wife's. She told him no more car parts in the kitchen sink! 😮 That toothbrush has been in lots of little spaces but not recently around my teeth 😬🪥😁 3 Quote Link to comment Share on other sites More sharing options...
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