2.3L ('02-'11) DIY HOT TANKING (better than I could've hoped for). 2.3 head over 2.5 block

[DaveH]

I've got a lot more time than money. Automotive services are scarce around here and the ones that are available are backed up "Months"!! So I started googling DIY HOT TANK. I decided I'd start small and simple. Bought a used camp stove for $100. Used Simple Green concentrate with water for cleaning solution. Was considering reusing pistons as the donor 2.5 short block for my 2.3 over 2.5 build. The engine was in really good condition. NOTE: (checking CarFax was a killer move for this one). Turned out the previous owner of the Ford Fusion was a maintenance nut. Changed oil religiously for the 6 years of the life of this vehicle. I really considered not taking it apart after looking at the bearings and journals. BUT, it was already apart so why not? Going to replace rings and bearings, hone the block.
I started with the pistons as I may or may not decide to re use them. They all measured in spec and had very little to no wear on the skirts. I used a shallow pan for the crowns as I didn't want to somehow affect the skirt coating. WOW, they cleaned up awesome! There are a lot of bolts I'll re use. So I tried them next. Came out looking brand new. Later I will use a little deeper pan I'll make from scrap steel for cooking that front cover. Again, I'll submerge it to the Clutch fan bearing but leaving the bearing out of the water Simple green mix. I don't want to chance damage to the bearing itself. After that I'll cut down a 55 gallon steel drum just tall enough to cover the main block and tank it. Never again will I have to run 40 mile round trip to hot tank, do it again to pick them up and pay them to do it. Total investment so far $120 bucks. We'll see how that crusty cover comes out.

 

[RobbieD]

Interesting, and great idea.

What was your mix ratio, and how hot did you let the solution get?

The results look great. Thanks for the post.

 

[DaveH]

Interesting, and great idea.

What was your mix ratio, and how hot did you let the solution get?

The results look great. Thanks for the post.

I start out very conservatively. Really I didn't mix it, just poured until that shallow pan looked greenish. Maybe a 1/2 cup. I didn't want the water to get too hot so I heated it to about steamy on mid level on the temp gauge.

 

[DaveH]

Well did the block today. Gotta say worked pretty well. Of course the garage wasn't closed up during the clean up.

 

[pjtoledo]

I've got a lot more time than money. Automotive services are scarce around here and the ones that are available are backed up "Months"!! So I started googling DIY HOT TANK. I decided I'd start small and simple. Bought a used camp stove for $100. Used Simple Green concentrate with water for cleaning solution. Was considering reusing pistons as the donor 2.5 short block for my 2.3 over 2.5 build. The engine was in really good condition. NOTE: (checking CarFax was a killer move for this one). Turned out the previous owner of the Ford Fusion was a maintenance nut. Changed oil religiously for the 6 years of the life of this vehicle. I really considered not taking it apart after looking at the bearings and journals. BUT, it was already apart so why not? Going to replace rings and bearings, hone the block.
I started with the pistons as I may or may not decide to re use them. They all measured in spec and had very little to no wear on the skirts. I used a shallow pan for the crowns as I didn't want to somehow affect the skirt coating. WOW, they cleaned up awesome! There are a lot of bolts I'll re use. So I tried them next. Came out looking brand new. Later I will use a little deeper pan I'll make from scrap steel for cooking that front cover. Again, I'll submerge it to the Clutch fan bearing but leaving the bearing out of the water Simple green mix. I don't want to chance damage to the bearing itself. After that I'll cut down a 55 gallon steel drum just tall enough to cover the main block and tank it. Never again will I have to run 40 mile round trip to hot tank, do it again to pick them up and pay them to do it. Total investment so far $120 bucks. We'll see how that crusty cover comes out.

that bearded guy in the middle picture looks kind of familiar.

didn't realize simple green worked that good when heated.

 

[DaveH]

Definitely helps when you have a good clean engine to start with!!! But, yeah, it really works well if you have the time to diddle around like I do. lol

 

[pjtoledo]

those head bolts are torque to yield, don't re-use them.
from the 2010 Fusion manual.

tightening: in standard circular pattern starting in center.
stage 1: 7 Nm or 62 INCH POUNDS
stage 2: 15 Nm or 133 INCH POUNDS
stage 3: 45 Nm or 33 Foot Pounds
stage 4: turn 90 degrees
stage 5: turn an additional 90 degrees

 

[DaveH]

those head bolts are torque to yield, don't re-use them.
from the 2010 Fusion manual.

tightening: in standard circular pattern starting in center.
stage 1: 7 Nm or 62 INCH POUNDS
stage 2: 15 Nm or 133 INCH POUNDS
stage 3: 45 Nm or 33 Foot Pounds
stage 4: turn 90 degrees
stage 5: turn an additional 90 degrees

Absolutely right! I mic'd the old ones 2.3 and the 16's out of the newer engine. Those 16's were .089" longer. I suspect they "stretched" or could be just different manufacturing but anyhoo, I've already ordered the OEM bolts from Ford. (I'm on the bottom end). Talking about Main bolts. Sorry. The Head bolts I knew about and will be going new with those too! This is the first engine I've done where I really have paid attention to every little thing that I'm aware of. (not saying much). lol.

 

[DaveH]

Absolutely right! I mic'd the old ones 2.3 and the 16's out of the newer engine. Those 16's were .089" longer. I suspect they "stretched" or could be just different manufacturing but anyhoo, I've already ordered the OEM bolts from Ford. (I'm on the bottom end). Talking about Main bolts. Sorry. The Head bolts I knew about and will be going new with those too! This is the first engine I've done where I really have paid attention to every little thing that I'm aware of. (not saying much). lol.

PJtoledo, I'm ordering parts for the short block. Ford wants 60 bucks a piston for a ring set $240 total. That sound right? So many choices cast iron, moly chrome?

 

[scotts90ranger]

Moly rings last longer but take longer to break in and are harder on the cylinder walls, depending on the goal I'd probably just stick with iron. I've had good luck with aftermarket rings on stuff, for the cheap ones check the gap...

 

[DaveH]

Thanks Scott, got hit with a bit of sticker shock. The last engine I built was in 17. The short block I'm assembling is from a 2.5 Ford Fusion. 60 bucks a hole for iron rings surprised me. That is aftermarket........ Some cheaper sets out there but manufacturers I've never heard of C.T.I for one.

 

[rubydist]

How many miles are on those pistons? They look really good from the pics.

 

[pjtoledo]

checking the usual sources for the midwest.
you're actually ahead of me in the 2,5 engine rebuilding.
I'm still in the "honey can I buy some more parts" phase

2016 FORD FUSION Piston Rings Parts & Accessories | Summit Racing

 

[DaveH]

How many miles are on those pistons? They look really good from the pics.

This engine came up for sale and I checked the cArFax on the vehicle. The owner changed oil in this car every 3k religiously. The mileage on the car was 87K.

 

[DaveH]

checking the usual sources for the midwest.
you're actually ahead of me in the 2,5 engine rebuilding.
I'm still in the "honey can I buy some more parts" phase

2016 FORD FUSION Piston Rings Parts & Accessories | Summit Racing

Mine is awesome. She knows that when I get a project in mind just let me do it.............. It usually turns out right! Earned some good boy points in 30 years.