2.2 Turbo RS2000 16V Engine Build

[blacksofstichill]

Yes indeed Stu! Silver on the sump, Grey on the Cam Cover.....all will be revealed in my next update, cheers!

[Stu]

Very good. Carry on!

[blacksofstichill]

I don't want to keep Stu in suspense any longer so........sump cleaned up and ready for painting -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0318.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0319.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0320.jpg

 

Primed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0321.jpg

 

Basecoated -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0322.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0323.jpg

 

With the paint drying I spent some time cleaning up the cam cover -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0324.jpg

 

Then onto lacquering the sump -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0325.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0326.jpg

 

New Gasket Fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0327.jpg

 

Bolted onto the engine block -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0328.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0329.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0330.jpg

 

The eagle eyed amongst you would notice I'd just painted the sump plug too, this was to save masking that area, I don't want to leave it silver -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0331.jpg

 

Sump Plug removed, new washer to the left -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0332.jpg

 

Sump Plug taken back to bare metal and new washer fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0333.jpg

 

Sump Plug refitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0334.jpg

 

Engine flipped back over -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0335.jpg

 

Cam Cover Primed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0336.jpg

 

Basecoated in Ford Mercury Grey (Mk4 Escort/Mk3 Fiesta, etc colour) -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0337.jpg

 

Lacquered and laid onto the head to let the paint cure -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0338.jpg

 

Starting to take shape as it's coming together now -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0339.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0340.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0341.jpg

 

Once the cam cover had been left to cure over night I fitted the gaskets -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0342.jpg

 

Fitted and bolted down -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0343.jpg

 

I used new Stainless Steel Button Head bolts for this which I had in stock, seemed a shame to use the old bolts on something that's so noticeable -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0344.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0345.jpg

[sidrick]

Niiiiiiiiiice.

[blacksofstichill]

Cheers, glad you like it so far! This is basically the stage that the engine would be left at (other than a flywheel and crank pulley) when I was saying the cost was £650 plus vat for labour to build one of these. After this stage it's either up to the owner to build up the rest or it's extra to let me carry on and do the rest. This build goes much further though so there are plenty more photos still to come!

[Stu]

Nice work chap. Did you mask off the mounting bolt holes on the cam cover? I've had some leak here after painting before.

[blacksofstichill]

Thanks Stu! No, I didn't mask of the bolt holes on the Cam Cover I'm afraid. I've done them before without any trouble but it's something worth keeping an eye on certainly, cheers!

[blacksofstichill]

Exhaust Manifold Studs fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0346.jpg

 

New Gasket Fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0347.jpg

 

Stainless Steel Exhaust Manifold supplied by Liam (johned84 on rs2000-16v.com) bolted up to the head -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0348.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0349.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0350.jpg

 

Thermostat Housing needed a clean up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0351.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0352.jpg

 

All Cleaned up, removed the fan switch as it was an air-con type and David's car hasn't got air-con so his existing fan switch will have to be re-used -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0353.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0354.jpg

 

Crank Pulley in need of a clean -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0355.jpg

 

Cleaned up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0356.jpg

 

 

Primed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0357.jpg

 

Painted in Gloss Black -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0358.jpg

 

Inlet manifold will be the next thing to clean up, fit new injectors to the fuel rail, etc, here's how it stands just now -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0359.jpg

[blacksofstichill]

stripped the plenum, inlet, fuel rail, etc. Inlet was a bit grubby -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0360.jpg

 

It's a pig of a shape to try and clean but I cleaned it up for painting as best as I could -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0361.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0362.jpg

 

Masked it off -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0363.jpg

 

Sprayed with Silver Engine Enamel -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0364.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0365.jpg

 

RS Fuel Rail (bottom) alongside a Nissan 200SX Fuel Rail -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0366.jpg

 

We need the injectors from the 200SX rail so we can fit them into the RS one to deliver the extra fueling the engine will need. Nissan Injectors removed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0367.jpg

 

RS Fuel Rail stripped of it's injectors, fuel pipes and Fuel Pressure Regulator -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0368.jpg

 

After a bit of a clean up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0369.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0370.jpg

 

Nissan Injector on the left, RS Injector on the Right, note the O-ring at the bottom is larger on the RS, these need to be swapped over so the Nissan Injectors will seal in the RS Fuel Rail -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0371.jpg

 

Nissan Injector with the RS lower O-ring fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0372.jpg

 

All Injectors fitted with the RS lower O-ring and ready to fit to the RS Rail -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0373.jpg

 

Nissan Injectors fitted to the RS rail -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0374.jpg

 

The retaining caps for the Nissan Injectors must also be used as the RS ones are not compatible, these ones were a bit grubby -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0375.jpg

 

All cleaned up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0376.jpg

 

and fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0377.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0378.jpg

 

I haven't refitted the Fuel Pressure regulator as an uprated one will need to be fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0379.jpg

 

New O-rings fitted and it's ready to fit to the inlet -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0380.jpg

 

Fitted to the inlet -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0381.jpg

 

Plenum was also a little bit grubby -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0382.jpg

 

All cleaned up, it was tempting to paint this as well but it's in good cosmetic order so I didn't see any real need -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0383.jpg

 

Insulator Gasket ready to fit -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0384.jpg

 

Inlet slotted onto the studs -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0385.jpg

 

New Gasket fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0386.jpg

 

Plenum bolted up, at this stage I've left off the Engine wiring loom as I know it will need to be adapted to suit the Nissan Injectors -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0387.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0388.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0389.jpg

[HIGHTOWER]

This is an awesome build! LOVE the attention to detail! Will we be seeing this fitted at the end?

[sidrick]

This is an awesome build! LOVE the attention to detail!

 

 

Yup. Best thread on here in ages.

[blacksofstichill]

Thanks for the positive comments, really appreciate that and glad you're finding it interesting.

 

Fuel Pipes ready to be re-fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0390.jpg

 

Fitted and clipped into place -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0391.jpg

 

Crankcase Vent Pipe, etc before cleaning -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0392.jpg

 

After a good clean up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0393.jpg

 

And coated with silver engine enamel -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0394.jpg

 

To avoid the problem of boost pressure entering the crankcase through the inlet manifold I altered the crank vent pipework -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0446.jpg

 

I removed a one-way valve from a servo pipe on an MG ZR I'm breaking -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0447.jpg

 

Cut the Vent Pipe back at the inlet end -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0448.jpg

 

Fitted the one-way valve -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0449.jpg

 

All back together -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0450.jpg

 

 

Fitted at the front -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0395.jpg

 

And at the back -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0451.jpg

 

The setup above is really just to do as much as I can here on the engine before it goes away to be fitted, wired and plumbed in. When that happens he may chose to fit a catch tank or vent the crankcase to the inlet but I'll leave that decision to the man fitting it as it makes more sense to cut and fit pipework with everything in place in the car. As it is the valve I've fitted will prevent boost pressure entering the crankcase but may not be suitable in the long term as prolonged boost pressure will still prevent the crank from venting as it should.

 

Crank Pulley bolted on -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0397.jpg

 

And that's how it stands just now, getting there! -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0398.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0399.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0400.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0401.jpg

 

Water Pipe as removed from the original engine -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0402.jpg

 

Cleaned up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0403.jpg

 

Painted with Silver Engine Enamel -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0404.jpg

 

Water Pump is in good order but very dirty -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0405.jpg

 

Pulley removed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0406.jpg

 

Cleaned up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0407.jpg

 

Pump painted in Silver Engine Enamel -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0408.jpg

 

Pulley Primed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0409.jpg

 

Pulley Painted in Gloss Black -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0410.jpg

 

Lifting Eyes and Engine Mount Bracket as removed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0411.jpg

 

Cleaned Up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0412.jpg

 

Primed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0413.jpg

 

Basecoated in Moondust Silver and Lacquered -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0414.jpg

 

I'd just noticed Hightower was asking if I'd also be fitting the engine but sadly in this case I'm not, the engine is heading up to Aberdeen to be fitted by a garage up there. However, the owner of the car has promised to take plenty of pics so hopefully I can get some from him and post them up here for you.

 

At the moment I'm just finishing a full rebuild of a Mk2 Cortina 1600E Crossflow engine which I've rebored, converted to unleaded, etc and next week I'm starting another RS2000 Turbo engine build, this time a 2.0 with Forged pistons and rods. If there's interest in them I'll happily post them up here.....don't want to bore anyone though!

[blacksofstichill]

Water Pipe Fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0415.jpg

 

Water Pump Fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0416.jpg

 

Engine Mount Bracket Fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0417.jpg

 

Lifting Eyes Fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0418.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0419.jpg

 

Throttle Body in need of a good clean up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0420.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0421.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0422.jpg

 

All stripped -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0423.jpg

 

All cleaned up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0424.jpg

 

Throttle Body onto the centre lathe -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0425.jpg

 

Bored very slightly and tidied up at the inlet edge -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0426.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0427.jpg

 

Back off the lathe and ready for a coat of paint -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0428.jpg

 

Primed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0429.jpg

 

Basecoated in Ford Mercury Grey and lacquered -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0430.jpg

 

Brackets, etc were painted in Silver Engine Enamel -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0431.jpg

 

David's Car is a non air-con model but out donor engine had air-con, as a result, the bracket on the front of the block for the alternator, etc was different, however a dig through my spares turned up a non air-con bracket -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0432.jpg

 

Power Steering Pump and Tensioner removed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0433.jpg

 

All Cleaned up -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0434.jpg

 

Bracket Primed -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0435.jpg

 

Bracket Painted in Ignition Red Gloss -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0436.jpg

 

Throttle Body rebuilt and ready to fit with New Gasket -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0437.jpg

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0438.jpg

 

Plenum Bracket fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0439.jpg

 

Throttle Body fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0440.jpg

 

Throttle Cable Bracket fitted -

 

http://blackengineering.co.uk/images/David-Newman-2.2-Turbo-RS2000-Engine/0441.jpg

[hicksy]

I really love this thread!

 

Its really interesting seeing what goes on with a rebuild like this!

 

Keep up the good work!

[lee grout]

This is flippin' awesome . I dont know a lot engine wise but your posts are informative without baffleing my brain! Im sure there will be interest in another build. Look forward to the next instalment.