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2.2 Turbo RS2000 16V Engine Build


blacksofstichill

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Hi all, I've just signed up here although I've been on many times before checking out the projects, etc and some of you may already know me as a member on RS2000-16v.com. I've recently carried out an engine build for someone on that forum and after speaking to a good friend of mine he convinced me to put a thread up on here about it. Apologies in advance to anyone who's already seen the build on the RS2000-16V forum!

 

The owner of the car David was busy getting his RS2000 4x4 bodywork into tip-top condition and wanted to have a Turbo engine in place once it was done. With this in mind he bought a spare 2.0 RS engine and a 2.3 Galaxy Engine and our plan is to combine the two engines to make a 2.2 Low Compression Engine which will be suitable for Turbocharging using standard components.

 

So, the work began when this arrived at my Workshop Door, the 2.3 Engine -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0001.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0002.jpg

 

Getting straight into it I got the Clutch off -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0003.jpg

 

Flywheel off -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0004.jpg

 

Engine Stand Bracket bolted on -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0005.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0006.jpg

 

Onto the Engine Stand and into the Workshop -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0007.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0008.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0009.jpg

 

Cam Cover off -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0010.jpg

 

Timing Covers off -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0011.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0012.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0013.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0014.jpg

 

Cams out -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0015.jpg

 

Cylinder Head off -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0016.jpg

 

Chains out -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0017.jpg

 

Engine flipped over -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0018.jpg

 

Sump off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0019.jpg

 

Pistons and conrods out -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0020.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0021.jpg

 

Main Bearing Caps off -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0022.jpg

 

Crankshaft is in good order but sadly won't be needed for this build -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0023.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0024.jpg

 

Crankshaft Out -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0025.jpg

 

Bores are in good order -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0026.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0027.jpg

 

Pistons and rods, etc set aside to be cleaned up later -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0028.jpg

 

 

I'll add the updates in stages as I'll mostly be copying and pasting from an existing thread on the other forum, it's very pic heavy as you can see but hopefully this'll be okay to get started with. Cheers! Gary

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i'll read this a second time gary lol

 

Cheers Marc!!

 

Nice read, keep it up :thumb:

 

Thanks, much appreciated, hopefull you'll not get too bored once I go into detail with this!

 

Block is now bare and ready for some reworking -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0029.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0030.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0031.jpg

 

This Oil Feed needs to be blanked off which used to feed the balancer shafts -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0032.jpg

 

Drilled out -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0033.jpg

 

Tapped -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0034.jpg

 

Bolt loctited in, job done -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0035.jpg

 

Digging into my spares I found a half moon casting so I could see where the mismatch piece needed to be made for the block -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0036.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0037.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0038.jpg

 

Onto the milling machine to machine up the surface of the block where the piece will fit in -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0039.jpg

 

Before

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0040.jpg

 

After

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0041.jpg

 

I got a suitable bit of steel to make the mismatch piece out of -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0042.jpg

 

Did a bit of measuring to get the angle correct -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0043.jpg

 

Milling up the piece of steel -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0044.jpg

 

A quick check to see if the angle is correct -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0045.jpg

 

Some more milling -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0046.jpg

 

Doesn't look to bad at all, will double check clearance from the chain when it's all together but it looks to be okay when I mocked it up with the crank and pump in place -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0047.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0048.jpg

 

Drilled and tapped the engine block -

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0049.jpg

 

6.1mm Hole drilled in the mismatch piece -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0050.jpg

 

To make the stud for fitting the mismatch piece I used an M7 x 1.0 bolt -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0051.jpg

 

Turned down part of it to 6mm -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0052.jpg

 

Threaded that part to M6 x 1.0

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0053.jpg

 

 

Cut the bolt head off to leave me with a stepped diameter stud -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0054.jpg

 

The M6 thread is a nice snug fit in the block and the M7 thread being slightly larger holds the block in place and allows an M7 nut for the timing cover bolt.

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0055.jpg

 

Fitted into place -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0056.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0057.jpg

 

 

Cheers!

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Cheers! Just noticed you're from Aberdeen, that's the area where the owner of this Engine is from, it's being mapped at Wallace Performance next month if all goes to plan.

 

Timing cover laid into place to see how it looks -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0058.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0059.jpg

 

With that out of the way it was time to Hone the Bores in the Block

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0060.jpg

 

Honing Bar in place -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0061.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0062.jpg

 

It didn't take a lot of work to get them to come up mint as they were already in good order -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0063.jpg

 

The engine block is in good cosmetic order, so much so that you can hardly tell I've cleaned this side of it, Before -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0064.jpg

 

After -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0065.jpg

 

Cleaned up the other side of the block which was mostly just dusty, from this -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0066.jpg

 

to this -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0067.jpg

 

Block now set aside, cleaned up, honed and ready for painting -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0068.jpg

 

I'll keep adding updates as soon as I can, cheers!

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We're using the standard 2.3 Pistons for this, although it will be turbo'd we're not planning on huge amounts of boost with 200bhp being the target figure we want to achieve. There's already a 2.3 Low Boost Turbo RS2000 using skimmed standard Pistons which has proven to be reliable and runs around 200bhp at the moment, if we were aiming any higher though it would definitely have to be forged pistons and rods.

 

Now I'm ready to make a start on the pistons and rods, here they are as removed from the engine -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0069.jpg

 

Rings off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0070.jpg

 

On the left I have a 2.0 RS Conrod, on the right I have a 2.3 Conrod, if you look closely you'll see that there's a small hole drilled in the 2.0 rod and the 2.3 rod is blank in the same area. These holes are for oil spray to cool the underside of the piston and since I'm using the 2.3 rods I'm going to drill them in the same way as the 2.0 ones.

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0071.jpg

 

Using a 2.0 Piston, rod and bearing shell I set up a little jig on the milling machine so I could accurately drill the same hole in the 2.3 Rods -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0072.jpg

 

Checking the alignment of the drill with the bearing shell -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0073.jpg

 

Centre Drilled -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0074.jpg

 

Drilled right through with a smaller drill -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0075.jpg

 

Drilled partially through with a larger drill to the same depth as it is on the 2.0 rods -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0076.jpg

 

Job Done -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0077.jpg

 

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0078.jpg

 

The pistons needed a good clean up, the ring grooves were carboned up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0079.jpg

 

A Piece of old Piston ring makes a great scraper for cleaning out the ring grooves -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0080.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0081.jpg

 

Grooves cleaned out -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0082.jpg

 

All pistons, rods and main bearing caps cleaned and degreased -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0083.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0084.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0085.jpg

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really good thread this, i am no engineer, but can well appriciate the work going into this, keep up the great work :thumb:

 

Thanks, much appreciated. Luckily I have a lot of kit in my own workshop so I've been able to do all of the work myself rather than passing it on to anyone else.

 

 

What will the final compression ratio be with this package?

 

It works out to be 8.72:1, that's without any skimming of pistons, decompression plates or anything like that.

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Ah right, I didn't catch what head you were using? I was under the impression using the 2.0 head on the 2.3 bottom end gave you a raised static CR.

 

8.7:1 should be fine for 200bhp with the right choice of cams (most likely the OE n/a ones to give it a bit of overlap).

 

I really like the i4 engine. It's much better than the zetec in some ways, shame it's a bit of a lard-arse.

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Sorry, I didn't really explain this properly in the beginning, you're right in saying that the 2.0 head on the 2.3 bottom end raises the compression, that's quite a common conversion to give RS2000s a 2.3 engine as you'll no doubt already know. Some people leave the compression higher and some people have the pistons skimmed to reduce the compression slightly.

 

This Build is the 2.3 Block, pistons and rods mated to the 2.0 head and using the standard RS cams. However, instead of using the 2.3 Crank as would be done on the 2.3 conversion we used the 2.0 crank to reduce the stroke and bring the compression ratio down which is why it comes out as a 2.2 (2169cc to be exact).

 

I love the I4 engine and the way it pulls even as standard but you're right, it's a very hefty engine!

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