IMG_5033

Ford Escort MK4 RS Turbo Series 2

 

 

Engine

 

•Engine re-bored by 0.5 mm to give 1617cc

•New Mahle pistons and ring set, piston crowns machined down by 60 thou to give compression ratio of 7.75:1

•Exchange original crankshaft

•New main bearing shells

•New big end bearing shells

•New piston con rods

•Skimmed and lightened fly wheel

•Head skimmed by 5 thou

•New oil pump and strainer

•New water pump

•Larger capacity Ford Motorcraft EFL90 oil filter (Cosworth 4WD)

•Running fully synthetic Castrol RS 10w60 oil

 

•New uprated valve stem oil seals modified by Ahmed Bayjoo

•New valve stem sleeves

•AP Borg and Beck high performance 4 point paddle clutch

•AP Borg and Beck high performance clutch cover

•Machined and re-profiled valve seats

•Nippon Denso PK20PR-P8 platinum tipped spark plugs

 

•Kent CVH 35 cam shaft

•Collins Motorsport vernier cam pulley

 

•Garrett AirResearch TO3 Turbocharger machined to accept Sierra Cosworth compressor wheel with 60 trim and 0.48 A/R compressor housing plus modified exhaust housing and 360º thrust bearing

•Garrett AirResearch –31 wastegate actuator

•Pace intercooler with modified front bumper to allow greater air flow

•Custom intercooler water spray

 

•K+N panel air filter housed in cut down standard air box

•Magnex 3 inch stainless exhaust

 

•Engine max power output of 230 bhp at 6900rpm running a peak of 20psi of boost pressure holding 16psi to max rpm. Measured on Powerstation’s Sun dynonometer compensated for standard air temperature and pressure.

 

Engine Management

 

•Ahmed Bayjoo Motorola ECU microprocessor for ignition and boost control

•Ahmed Bayjoo Bosch ECU microprocessor for KE-Jetronic fuelling control

•Mechanical modifications to the KE-Jetronic injection system

•Rev limiter set to 7000rpm

•Modifications to the ports on the boost control, Amal, valve

•Charge carrier pressure feed pipe to fuel pressure regulator to improve high boost fuelling

•Cold start injector disabled

 

Brakes and Suspension

 

•Front and rear Spax top adjustable dampers with matched Spax springs

•Adjustable front track control arms set at 2 degree negative camber, zero toe

•Rear wheels set to 1 degree negative camber, zero toe

•Complete set of Powerflex polyurethane bushes on front and rear suspension

•283mm vented front brake disks (Sapphire Cosworth 2WD front)

•Mintex M1155 front race brake pads (Mintex code MDB1236)

•Goodridge stainless steel braided brake hoses on front and rear brakes

•Castrol DOT 4 brake fluid

•2.4 turn lock to lock quick steering rack

•Steering rack lowered by 20 mm to reduce bumpsteer

•Mechanical ABS removed

 

Wheels and tyres

 

•Dunlop 2 x SP2020 195/50 x R15 V wet tyre option on RS Turbo Series 2 6x15 alloys

•Dunlop 2 x SP2000 195/50 x R15 V wet tyre option on RS Turbo Series 2 6x15 alloys

•Yokohama A032R 195/55 x R15 Vdry tyre option on RS Turbo Series 1 6x15 alloys (32 psi hot or 26 psi cold)

 

New Ford original equipment replacements include

 

•Front CV joints

•Hydraulic lifters

•Valve rocker arms

•Cam belt

•Alternator belt

•Fuel filter

•Distributor and rotor arm

•Oil breather/separator and miscellaneous vacuum hoses

•Steering rack

•Steering rack ball joints

•Rear tie bars

•Rear brake shoes

•Rear brake cylinders

•Rear wheel bearings

•Ford reconditioned gearbox with Motul 75w90 fully synthetic gear oil

•Clutch thrust bearing

•Clutch ratchet and pawl

•Willans four point harness fitted to drivers seat

 

 

 

Done