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Escort RS2000 4x4 2.0 Turbo Conversion


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Time to add another of my projects on here, this one is for a Customer from Bournemouth and originally started as job to rebuild an engine, however I now have the complete car here to carry out the project from start to finish so I thought some of you might find it interesting.

 

The story starts back in 2009 when Olly (my customer) saw an engine for sale on ebay, it was an I4 out of an RS2000 that had be turbo'd and built to handle 300+ bhp according to the listing. It didn't sell the first week, the second time it was up it did sell for £600 odd but he missed the auction. he spoke to the seller a few days later who had not been contacted by the original buyer so he agreed to sell it to him instead.

It was in a bit of a state as it had been stood for a few years on a pallet, under a tarp, it then lived down the side of of his house for 3 years. Here are some pics of it as it was before it came up to me -

 

http://i579.photobucket.com/albums/ss237/doctorevil72/DSC00981_zpsadce0ad2.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/DSC00982_zpsde4c0849.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/DSC00979_zps57e8216e.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/DSC00984_zpsbcc69822.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/rs2000/IMG_2941_zpseacc83e8.jpg

http://i579.photobucket.com/albums/ss237/doctorevil72/rs2000/IMG_2940_zps53473eb3.jpg

 

On the pallet ready to go:

 

http://i579.photobucket.com/albums/ss237/doctorevil72/rs2000/IMG_2942_zps4cbc7047.jpg

 

And after arriving safely here -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0001.jpg

 

clutch and flywheel removed, it has a 4 paddle clutch plate as you can see -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0002.jpg

 

Engine stand bracket bolted on and engine uprighted on the pallet -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0003.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0004.jpg

 

My Old Man ready to leap into action with the Forklift -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0005.jpg

 

Just ouside my workshop door -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0006.jpg

 

Lifted up onto the engine stand at the door and removed from the pallet -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0007.jpg

 

Into the workshop now for a good look round it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0008.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0009.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0010.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0011.jpg

 

Escort RS Turbo Manifold has been mated to the RS2000 Flange, it makes a couple of studs very tight for space but looks to have done the job -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0012.jpg

 

Oil Return fed back into the block -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0013.jpg

 

Oil feed pipe T-pieced into the block at the oil pressure switch -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0014.jpg

 

Non-standard Fuel Rail and Injectors -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0015.jpg

 

More pics, etc to be added soon, cheers!

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Nice write up so far, I look forward to more :-)

 

Thanks, I hope you'll find it interesting. I'll be concentrating on the engine to start with before moving onto the car itself so there's plenty of work ahead. :cheers:

 

i think i might know your customer, i bought a bunch of parts off him a little while back

 

Quite possibly, he's had a few RS2000s over the years, did you meet him when you bought the stuff?

 

 

Can't wait to see this build :D

 

Great stuff, cheers! :cheers:

 

 

Definitely going to be following this one :)

 

*sits down to get comfy*

 

Thanks, you'd best get comfy, there's plenty to see on this one as it progresses. :)

 

Starting to strip it down, engine mount off, water pump off, alternator and power steering pump and bracket all off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0016.jpg

 

Exhaust Manifold off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0017.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0018.jpg

 

Inlet Manifold off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0019.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0020.jpg

 

Thermostat Housing removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0021.jpg

 

Cam Cover off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0022.jpg

 

Upper Timing Cover removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0023.jpg

 

Cams removed and it's ready for the head to come off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0024.jpg

 

Cylinder Head removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0025.jpg

 

Exhaust Ports -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0026.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0027.jpg

 

Inlet Ports -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0028.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0029.jpg

 

Valve Spring Caps are visibly different from standard so I decided to remove 1 valve just to check them out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0030.jpg

 

Valve Spring compressed and collets removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0031.jpg

 

Valve Springs are not standard and the Spring Caps are lightweight and non-magnetic, I'll guess at them being made from Titanium but I could be wrong, either way they're definitely uprated items -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0032.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0033.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0034.jpg

 

The Head itself has some corrosion and carbon build up but it will hopefully all clean up fine -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0035.jpg

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yeah he lived in boscombe. at the time he had a silver mk5 rs and a blask mk6 4x4. i bought my skirts and spats off him. the black 4x4 he had originally belonged to my friends mum christina weaver (chair of the hampshire rs owners club)
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yeah he lived in boscombe. at the time he had a silver mk5 rs and a blask mk6 4x4. i bought my skirts and spats off him. the black 4x4 he had originally belonged to my friends mum christina weaver (chair of the hampshire rs owners club)

 

That's the guy, I didn't know where he bought the black 4x4 from but I know he sold it to Dean Weaver (I presume that's your mate unless he has a brother?) when he was finished with it. Olly's a really good guy, put himself to a lot of time and and effort so I could do this job for him. :cheers:

 

 

here we go again......yet another great start, to another great thread :thumb:

 

Thanks, hope you enjoy following this one too. :cheers:

 

With the head off you can see the pistons aren't standard -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0036.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0037.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0038.jpg

 

So, eager to see exactly what else was in there I cracked on with the strip-down, crank pulley off -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0039.jpg

 

Lower Timing Cover off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0040.jpg

 

The Bolt for the Pump Sprocket had seen a bit of action -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0041.jpg

 

Pump Sprocket off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0042.jpg

 

Can you spot the conrod in the background? -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0043.jpg

 

Crank Sprocket off, chains out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0044.jpg

 

Oil Pump out which incidentally looks mint -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0045.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0046.jpg

 

Oil Filter off, crank sensor out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0047.jpg

 

Adaptor for Oil feed to turbo at the oil pressure switch -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0048.jpg

 

and removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0049.jpg

 

Crank vent pipe removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0050.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0051.jpg

 

Engine Flipped over -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0052.jpg

 

Sump off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0053.jpg

 

You can get a better look at the rods now, they're Forged items and going by the bolt heads they are from Cunningham Rods in the US -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0054.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0055.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0056.jpg

 

Baffle Plate off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0057.jpg

 

Pickup pipe off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0058.jpg

 

Rods numbered before removal -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0059.jpg

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haha small worl eh? i bought my current escort from dean. i used to go to school with his brother mark. and his mums the head of the rs owners club hampshire. thats black escort was a rusty bag of shite lol do u know dean or his family?
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haha small worl eh? i bought my current escort from dean. i used to go to school with his brother mark. and his mums the head of the rs owners club hampshire. thats black escort was a rusty bag of shite lol do u know dean or his family?

 

Definitely a small world! I don't know Dean but I know of him from when he was on the RS2000-16V forum a while ago and knew his mum had to do with the local RSOC. I'm not sure how many times that Black RS has changed hands since Olly had it but it was on gumtree for a shocking £3500 or thereabouts just recently and still didn't look all that great!

 

 

Impressive progress, not bad for a days work lol, wish i could get that much done!

 

Someones spent a pretty penny on that motor.

 

Thanks, much appreciated. The story was that the car this engine came from had a colossal amount of money spent on it, not just on this engine but it was also converted from 2wd to 4x4, had a different bodykit, etc. It's certainly got some nice bits on the engine front! :cheers:

 

Big End Shells are mint -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0060.jpg

 

As is the crankshaft -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0061.jpg

 

Pistons and rods out, The Pistons are Forged Arias Pistons and are in mint condition too -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0062.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0063.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0064.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0065.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0066.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0067.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0068.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0069.jpg

 

Back to the Engine Block now -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0070.jpg

 

Main Bearing Caps off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0071.jpg

 

Bearing shells are mint as are the main journals -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0072.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0073.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0074.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0075.jpg

 

Crankshaft out -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0076.jpg

 

Block flipped back over again -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0077.jpg

 

Having a good look at the bores you can see some scoring, this is more than just superficial marking and the scores are too deep for this block to be re-used again without reboring it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0078.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0079.jpg

 

The bore on this block is not standard, it had been bored out to 86.5mm and we want to re-use the good forged pistons and rods so it means we can't re-use this block at all for this build. So, the plan of action is to use another 2.0 block which I'll rebore to 86.5mm and that will mean we're starting with good fresh bores and mint forged pistons and rods. It should certainly be a good basis for a nice strong powerful engine. Cheers!

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