2.2 Turbo RS2000 16V Engine Build

[Stu]

Must be a small combustion chamber? In the region of 40cc's or something?

[blacksofstichill]

It is, yeah, on the RS Head I measured it to be 45cc. The Galaxy head has a larger combustion chamber so the opportunity to go lower compression is there but we wanted to have a happy medium here and using the standard components we felt the RS head was the right one to go for.

[Stu]

It is, yeah, on the RS Head I measured it to be 45cc. The Galaxy head has a larger combustion chamber so the opportunity to go lower compression is there but we wanted to have a happy medium here and using the standard components we felt the RS head was the right one to go for.

 

That's interesting. With a 2L zetec, a -3mm protrusion with a ~48cc chamber gives you around 7.6:1 with 88mm stroke. I suspect all the numbers will add up though!

 

What management are you going to use?

[blacksofstichill]

That's interesting. With a 2L zetec, a -3mm protrusion with a ~48cc chamber gives you around 7.6:1 with 88mm stroke. I suspect all the numbers will add up though!

 

What management are you going to use?

 

This is an 89.6mm bore using the 2.3 block but instead of being a 91mm stroke as it would have been with the 2.3 Crank, the 2.0 crank reduces the stroke to 86mm. I think I must have checked my calculations about 5 times before I was confident I had it right!

 

Originally it was going to be run on Megasquirt but it's now going to be Emerald as the owner of the car has struck a good deal with Wallace Performance to supply and fit that instead.

[Stu]

Interesting stuff. I used to run a little sideline doing MS mapping. Gave it up years ago though as most of the cars people brought to me (or dragged me to go map) were nowhere near ready for mapping and had tons of issues I wasn't willing to resolve.

 

Good luck with the build. I suspect it could make more power than your goal with the right choice of turbo. I'd go with a T34, run about a bar of boost and enjoy 250bhp. That's if the valvetrain will cope!

[sidrick]

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.

 

They've a good name since they changed ownership a few years back. Let us know how it goes as I've never actually used them.

[blacksofstichill]

I can imagine what half the cars were like when you went out to map them, I'd guess that you could spend a couple of days on some just trying to get it to a stage where it would be possible to map it!

 

This will certainly be interesting to see what it makes once it's up and running, although 200bhp was the initial goal I'd like to see it make 225bhp to be around Escort Cosworth Power as I think that's a good benchmark, if it can make that and prove to be reliable I'll be very happy with that. The owner of the car supplied the Turbo which is an ebay job, it's called a GT2528 but how that compares to any Garrett Turbo for example I'm not sure, I'll have some pics of it later on as I get some more info up though.

 

Here's the 2.3 Block all masked up on the engine stand ready for painting -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0099.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0100.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0101.jpg

 

Primed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0102.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0103.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0104.jpg

 

Glossed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0105.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0106.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0107.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0108.jpg

 

Masking off and it's looking good -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0109.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0110.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0111.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0112.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0113.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0114.jpg

 

Although the block looks orange in the Pics, I can assure you it'd definitely red when you see it in the metal!

 

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.

 

They've a good name since they changed ownership a few years back. Let us know how it goes as I've never actually used them.

 

I've never used them myself either but I think it was some of the RSOC lads up there that convinced David to give them a try, I'll certainly report back to let you know how they get on with it, cheers!

[Stu]

Looks good. I was going to ask if it was red or tractor orange? Ha ha!

 

Not heard of a GT2528. I wonder if it's a genuine Garrett turbo or some chinese hybrid? The proper GT25's start at GT2554 and then go up in size from there.

 

To be honest I think it'll be a bit small for what you want. That series of turbo, if it is T/GT25 based is pretty much flat out at 220bhp, quite inefficient with a lot of back pressure. As you know, not what you want when it comes to a relatively high compression turbo engine. I've run T25's before on this kind of engine and you can pretty much just unhook the wastegate and the back pressure of the turbo itself stops it boosting too high! Increases EGT's and makes it more det-prone though. One advantage though is practically zero lag and a very low boost threshold as it's so small!

 

Perhaps you could persuade the chap to find something a bit bigger/efficient?

[blacksofstichill]

Yeah, I don't blame you for wondering about the paint colour, I've been asked what shade of Peach it is and all sorts! It's actually called ignition red but for whatever reason it doesnt show up well under the lights when I photograph it.

 

This will be the turbo he has bought, perhaps not from the same seller but it will be the same turbo, I think it'll be a chinese Hybrid Chinese version as you say - http://www.ebay.co.uk/itm/Max-GT2528-TURBO...k-/170631598845

 

I think his intention will be to run with that and see how it goes for now and maybe change it at a later date if it doesn't live up to what he wants from it.

[blacksofstichill]

With the 2.3 Block set aside, the 2.0 engine arrived and I set to work on it -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0086.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0087.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0088.jpg

 

So, cracking on with it I got the Transfer Box off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0089.jpg

 

Gearbox off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0090.jpg

 

Alternator and Air-con off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0091.jpg

 

Inlet manifold off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0092.jpg

 

Clutch off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0093.jpg

 

Clutch has been fried and is just down to the rivets -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0094.jpg

 

Flywheel has seen a bit of heat too but nothing that won't skim clean on the lathe -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0095.jpg

 

Flywheel off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0096.jpg

 

Getting a bit dark for working outside but never mind! Power Steering Pump and Water Pump off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0097.jpg

 

Thermostat housing off, coil packs off and that's it ready to go on to the engine stand to be stripped -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0098.jpg

[mcflycossie]

Top stuff Gary

[blacksofstichill]

Cheers Ben!

[blacksofstichill]

Got the 2.0 engine in and onto the stand -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0115.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0116.jpg

 

Cam Cover off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0117.jpg

 

Timing Covers off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0118.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0119.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0120.jpg

 

Cams Out -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0121.jpg

 

Cylinder Head off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0122.jpg

 

Head certainly appears to be in good order, no cracking between the valve seats or plug hole as far as I can see and it's generally quite clean -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0123.jpg

 

Oil Pump Out, crank sprocket off, chains out -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0124.jpg

 

This needs to come out as it's just blanked off on the 2.3 Block -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0125.jpg

 

Done! Dipstick tube also removed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0126.jpg

 

4x4 Oil Filter adaptor also needs to be removed and fitted to the 2.3 block as David's RS is also 4x4 -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0127.jpg

 

Filter Adaptor, crank sensor and Oil Pressure Switch all removed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0128.jpg

 

Engine Flipped over -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0129.jpg

 

Sump off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0130.jpg

 

Oil Pickup and Baffle removed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0131.jpg

 

Crank is mint with no scoring, which is a good job as we need this to be fitted to the 2.3 block -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0132.jpg

 

2.0 Block now fully stripped and all parts set aside -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0133.jpg

[sortedford]

Looks like some good work going on

[blacksofstichill]

Thanks, much appreciated.

 

Since this engine will be turbo'd it will need an oil return fed back into the sump, I had another RS2000 Engine here which had been Turbo'd a good number of years back and after looking at how it had been done I decided to feed it back into the bottom of the block rather than into the sump itself. This saves having to do any work to the sump itself such as drilling or tapping holes or welding spigots on, etc and hopefully this will look like a factory job. I decided to feed the oil back in here -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0134.jpg

 

And rather than make up something to fit into the block I decided to use the dipstick tube left over from the Galaxy engine -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0135.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0136.jpg

 

Using this means I can replicate the existing dipstick hole at this point, angle the dipstick tube to suit and cut it to length, then a flexible pipe can be fed down to it from the turbo.

 

So, pilot hole drilled -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0137.jpg

 

Opened up with a bigger drill -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0138.jpg

 

Reamed to suit the Tube -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0139.jpg

 

Counterbored to suit the oil seal on the step of the tube -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0140.jpg

 

I angled the hole so it comes in just within the edge of the block so it doesn't interfere with the face where the sump will seal -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0141.jpg

 

Tube trial fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0142.jpg

 

The tube protrudes into the block too much as it is -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0143.jpg

 

So, I cut it back just below flush so there is no chance of it fouling the trigger wheel once the crank is fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0144.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0145.jpg

 

Dipstick tube turned around a bit, just to show the variation in angles it will allow me to have to suit the feed from the turbo, obviously it will still need to be cut to length when the time comes -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0146.jpg

 

Here's how the block looks from the outisde -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0147.jpg

 

New Main Bearing Shells for the crank -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0148.jpg

 

Fitted to the block -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0149.jpg

 

Crank cleaned up and fitted in place -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0150.jpg

 

Here you can see why I trimmed back the tube for the oil return as it is right next to the trigger wheel -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0151.jpg

 

Bearing shells fitted to the Main Caps -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0152.jpg

 

Main Caps fitted and Torqued down -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0153.jpg

 

Just a couple of other bits fitted before I tidied up the other day, half moon casting -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0154.jpg

 

 

Oil Filter adaptor and Crank Sensor -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0155.jpg

 

Coolant Pipe fitting screwed into block -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0156.jpg

 

Cylinder Head set aside, ready to be refurbished -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0157.jpg