Do you drive the Ford i4 8 valve DOHC engine?

[billjackson54]

Calling all MOC members with the 8 valve DOHC “i4” engine as fitted to Sierras and Granadas from 89 to 93. At some point in the near future, if not now, your Cam Cover is likely to start to leak. They tend to split and crack around the bolt holes and the material they’re made of becomes porous and your lovely clean engine isn’t any more. These cam covers are no longer available from Ford…and decent second-hand ones almost unavailable as the breakers would rather sell a complete engine than to break one for parts. There is the option of upgrading the engine to something newer, of course, but this is quite involved, complex and neither simple or cheap….and if your existing i4 is OK in all other respects, there is an alternative. I have found a company who will cast a shiny new cam cover for you, supplied with new gasket, stainless bolts and probably in your choice of colour for around £300. To proceed I need 10 interested people.
I recently found a “good” second hand cover after a very lengthy and almost fruitless search and it cost nearly £100….so a custom made alloy cover seems like a good idea to me….what about you?

[chris_cussen]

Re: Do you drive the Ford i4 8 valve DOHC engine?

First of all- damn, I had one of these engines with destroyed internals, could have made a fortune
Second, if you are looking for a cam cover these engines were also fitted to some Transits and Galaxy MPVs in a transvers application

[billjackson54]

Re: Do you drive the Ford i4 8 valve DOHC engine?

Sorry, Chris, but isn't that just the way it goes sometimes! On a point of information, the i4 was used in some petrol transits, but until reading your post I was unaware that the 8 valve engine was ever used in a Galaxy...there was a 2 litre engine, rapidly replaced with a 2.3 litre engine....but I had thought these were all 16 valve engines....the same block, but with a 16 valve head.
H

[copperleaves11]

Re: Do you drive the Ford i4 8 valve DOHC engine?

If this is a plastic component, is there any possibility of getting one scanned and 3d printed.

[billjackson54]

Re: Do you drive the Ford i4 8 valve DOHC engine?

Thank you copperleaves11...I have researched this and the process would require two stages: first a laser scan of the cover itself and the necessary reverse engineering to produce the file from which an accurate print could be made...priced at £600 inc VAT...and then the actual printing itself. In view of the heat / oil / stress on this component, a suitable material would need to be found...difficult if not impossible ? ...and the price quoted for producing covers in aluminium was going to be around £1000 per unit...as a solid block of aluminium would have to be machined with a huge amount of waste.
However...once I have a few more interested people I will revisit the idea of 3d printing. I am aware that the ball park figure of £300 is quite steep...but it's a fraction of the cost of replacing the engine. £200-£250 might buy a serviceable bare Zetec...but there are the ancillaries to buy, water pump problems to address, new manifolds, new exhaust system and new engine management to add to the shopping list..so suddenly £300 seems like a reasonable deal.

[A_Hogg]

Re: Do you drive the Ford i4 8 valve DOHC engine?

Mk 5 Ford Escort Rs 2000 had this engine. Maybe a long shot but could try owners club?

[keith_h]

Re: Do you drive the Ford i4 8 valve DOHC engine?

Anyone want to try an experiment (about £15 - £20). Thoroughly clean/degrease the original to make a plaster cast. Apply several/many layers of fibreglass using heat and chemically resistant resin. You will have to take advice on which is best to use (Google fetches up loads). Make sure both inside and outside are smooth. Now apply several thicknesses of Gold Roll Adhesive Reflective Temperature Heat Shield Wrap Tape. Silver is more often used but I thought Gold would look sprauncy. If the resin is good enough you shouldn't need the tape.

Good luck