Engine rebuilt

I spent the first part of my summer vacation to rebuild the damaged engine. 

New block and new pistons, and a new built loom.

Started without troubles, but I forgot to turn on the video recorder!

A couple of test runs without issues. Ahh I've missed this!

My family is a bit tired on me working on the engine but now I can take a real vacation and enjoy the short summer.

Meanwhile - read Croc's article Getting decent video audio on your Seven.

New engine block

New Cosworth pistons.
I reuse the rods as they're not damaged.

Finally, here it is!

I couldn't find a replacement Duratec 2.3 block in Europe so I had to order one from California.

GPWerks had both new and used blocks. It took a while to get it but eventually a brand new block arrived.

Beware of TNT Express! They're totally incompetent and should really change their slogan. I'm surprised they manage to deliver any packages at all!

Now I could start to rebuild the engine, I thought, until I dropped a spanner and damaged one of the main bearings.

I ordered new bearings from xpower-engines at eBay and they were very helpful and posted the bearings right away. I can start with other parts in the meantime.

New engine loom

Last time I rebuilt the engine I bought a generic Duratec loom from SBDev. Very nice quality and well made loom. But as it only had wiring for controlling the engine and not for fans, starter relays, dash gauges etc I made my own loom for that.

It worked fine but it looked like crap. Now when I'm waiting for engine parts and have nothing better to do I decided to do it again but with some more effort this time. I also wanted wiring for a few more sensors to the ecu and a future data logger.

The new loom have these connectors:

• Starter solenoid
• Starter relay
• Water temperature (dash)
• Alternator warning light 
• Fan 1
• Fan 2
• Fan relay
• Oil pressure sensor 
• Oil temp sensor 
• Fuel pressure sensor (future)
• Data logger (future)
• Chassis connector 
• MBE 1 (existing connector on engine loom)
• MBE 2 (new)
• +12
• GND

I started by doing a template with some wire, tape and zip ties.

Then the actual wires.

Lots of heat shrink tubing, and some of the connectors

And here it is!

Heat shrink tubing, the best since sliced bread

I haven't tested it in the car yet, but what could possibly gone wrong? ;-)