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Discussion Starter #1
So first off, just a bit of a thank you to all who came before me. I have been lurking the board the last couple months as I prepared to swap a blown engine.

I came into possession of a 02 2.0 SPI 'scort with a blown engine. I started work on it a couple weeks back (slow progress). I have already purchased a replacement engine, etc.

A little back story on the engine - My Dad, the previous owner, took the vehicle in for its 120,000 mile service visit. Normally, our family always services our own vehicles, but there was some circumstances keeping us busy at the time. He had the timing belt changed, 'supposedly' also had the whole nine yards, cooling flushing, sensor checks, etc etc etc.

Shortly after getting the car back from service, he noticed it was not running well at all. He took it back. They looked, and "couldnt find anything wrong". Fast forward two weeks. Frustrated, he takes it to yet another dealer to have it checked. They found a bad sensor, and 'supposedly' replaced. Fast forward 3 weeks. Engine still not running well.

This entire time, the temp gauge on the dash never indicates heat. not even slightly warm. Stays locked on cold. My mother drives the car downtown, parks. Goes to store. Comes back out an hour later. Goes to start the car, and it will not start. "Sounds like rattling marbles in a can" is how she described it. Dad parked car etc, until now.

Just a few days ago, I finished getting the blown engine pulled from the vehicle. Today, I spent some time disassembling it.

So i spent today taking all the accessories off, separating the trans axle, etc. Before calling it a night, i decided to go ahead and yank the head, and see what was up.

I was figuring maybe the dropped valve seat I've heard about, from overheating. Or maybe something else screwy like that.

Was I ever shocked when i pulled it off and noticed the number 4 piston was gone. Completely. There was literally. Nothing. Left. Looking at the bottom of the head, there are tiny melted pieces of metal all over in every cylinder, all the remaining pistons also have melted pieces of metal, and glancing past the rod in the 4th cylinder, i can see a tiny few fragments.

Most of my past experience is with 350 class chevy truck engines. Ive seen quite a few mishaps in my day, but this is the first time i have ever seen a piston completely disintegrated. Has anyone else ever experienced something like this in an escort? Any idea what would cause such a catastrophic failure?

Here are some pictures of the project so far. I have not had a chance to take pictures of the torn apart insides yet, as I want to get some good ones. I will Try and post tomorrow.

http://www.facebook.com/album.php?aid=83408&id=510278160&l=40e6b9786f

My Only Thoughts are that perhaps there was a combination of bad sensor and/or bad thermostat, causing the engine to overheat, causing the head gasket to fail. If this happened, and the engine was extremely overheated, I would imagine just a small amount of water hitting a superheated piston would be enough to cause something like this to happen. Is that possible, or am I way off base?

I think I have written down everything I need to do before dropping the new engine in, but if anyone has any advice of things to do that are commonly forgotten, I am more than open to receiving! Thanks in advance for your input!
 

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it dropped a valve seat - plain and simple, that 1 little seat will wreck the #4 piston depending on how long the motor was run after it dropped..... being it was your mom, she may have let it run like that for too long, perhaps even giveing it some throttle and just destroyed the piston with the seat bounceing around like a ping-pong ball in the cylinder.

as a note - these motors only have to overheat once in their life sometime to begin the dropped seat progression. Once the seat begins to work its way lose, and the valve hammers it back into place enough times, it will inevitably drop out from lack of metal in the seat area to hold it in any longer.

make sure to replace the head with one that has the updated valve seats to reduce the chance of this happening again.
 

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My only comment is Dang I wish I had your garage! You even have a nice table and chairs to sit down and take a break during the work. Is there a big-screen TV in there also? That would make my car work so much more enjoyable.
 

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Jeffescortlx said:
I'd like to see a pic of the head around the valves.
Your missing a valve seat right?

I have broke a piston once, only becaue the head of the valve broke off, does'nt compress real well. lolz
I remember those pics - now thats devastation, lol
 

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Discussion Starter #6
Hey Guys,

It is my dads shop - just finished his remodel last winter. And yes. Its is VERY nice. No TV - Yet, but its in the plans :)

Sorry about the pics - I will try and get them up tomorrow - spent all day yesterday running around and getting some more parts 8O
 

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Discussion Starter #7
Hello All,

As Promised, pictures of the inside - Please view the updated album here -

http://www.facebook.com/album.php?aid=8 ... 40e6b9786f

The carnage is... heartbreaking.

I am almost ready to drop the new engine in. Just a couple loose ends to tie up, timing belt install is waiting on new tensioner on order. Holiday weekend delaying that... bummer.
 

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That's one thing I never did when my engine blew: Removed the head and looked at the damage.

The nickel-sized hole in the back of the block was good enough for me.

Casey
 

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Discussion Starter #10
So if anyone wants a block/crank with a scratched up cyl wall (probably not) or a cyl head with piston bits embedded (probably not) or a 2.0 intake (maybe?) i will be posting details soon. Free. ;-)
 

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I'll take the upper intake manifold!!! pm me for more details :D

I need an extra one to send off with my 3.8tb for boring!
 

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Discussion Starter #12
Hi celery,

will try and get back to you as soon as my head is out of the car ;-)

today was one of those pita days. got the new engine dropped in and mounted.... that took all of 30 minutes. then i spent maybe.... 3 or 4 hours dinking around with the stupid clamps they give you with new cv boots. i finally gave up and zip tied em for now until i can find some better clips.

then, went to torque down everything in the wheel wells.... joy... tie rod end stripped on passenger side. so, yet ANOTHER trip to the parts store tomorrow. i think i am up to 20 now. please, let it stop :(

oh well, few days and i will have a nice new vehicle to drive around ;-)
 
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