Well it seems like the water leak has been stopped.  It was rapidly traced
to the T for the heater on the LHS (looking at the front of the car) "pump
to rad hose" with the water up to fan-on temperature.  This T is a 15 mm OD
plastic pipe bonded into the rubber and over the course of the 15 years the
car has been in existence it gradually collapsed inwards under the hose
clamp to the point where it would leak under high pressure.  By pure chance,
I had a piece of 13 mm OD thin walled steel pipe of the right length to hand
that was a drive fit into the plastic pipe to reform its shape and prevent
further collapse.  The car has now done around 20 miles in traffic, albeit
at lower ambient temperature but with the water up to fan-on temperature
without any apparent leakage.

 

As a matter of course when dealing with water leaks I removed the plugs to
see if there were any trace of water ingress into the cylinders commensurate
with a blown gasket.  No white traces on the plugs or on top of the pistons
that I could see so probably all is well but annoyingly the thread on my
compression tester was not long enough to engage with that in the head on a
Silver top Zetec so I will have to make an adaptor to be on the safe side.

 

I noted that the insulator on one of the plugs had cracked.  This is the
first instance of such a problem that I have encountered.  I went to buy a
new set of plugs only to find that the only suitable type at our local
friendly Halfords was the Champion version, gapped at 1 mm whereas my Haynes
manual says 1.3 mm gap for a Zetec.  What gap do others use (1.8 litre 115
Ps Escort derived build) and has anyone found an advantage in using a
particular plug type?

 

What was also interesting was that the tip-in/tip-out issue has now
diminished and I feel that it most likely relates to the air bypass valve
(ABV) cutting in or out.  Unfortunately the Zetec has a non-serviceable type
ABV whereas on the 2.0 DOHC engine in my Beauford it is possible to strip
and clean all the component parts.  In passing, I was not able to purchase
new engine mounts; probably as well as the apparent "separation" visible on
the gearbox end mounts from above is a design feature and when the engine
was jacked up all four mounts were found to be intact.  Another Red Herring!

 

Hamish

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