Escort RS2000 4x4 2.0 Turbo Conversion

[blacksofstichill]

surely you will be fitting a nice new shiny stainless rad or something?

 

Yeah, we have a new rad for the job, the old one is just for the trial fitment.

 

I thought you'd forgotten about us. Great work

 

Cheers!  I do have a bad memory but I hadn't forgotten about you!

 

What Sid said. 

 

Cheers!

 

It's like artwork, I would hate to get it oily/dirty!

 

Thanks, I should maybe have built 2 engines, one to use and one for show!

 

I've never seen any close up detail as to how anyone else has there water pipes connected to the turbo so I pretty much made this up as I went along. To join onto the existing system I needed to cut hoses and fit a metal sleeve in place with a spigot. In true scrapyard challenge style I found what I needed in stock already, once from an MG ZR, the other from a Transit Connect -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01629.jpg

 

The required sections were cut from each pipe -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01630.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01631.jpg

 

Painted up and ready to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01632.jpg

 

First one fitted into the Radiator hose, again I also found a section of suitable hose to fit onto the spigot which will eventually fit onto the banjo fitting on the turbo -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01633.jpg

 

Hose held roughly in the place it will sit when connected to the banjo bolt -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01634.jpg

 

Next one fitted, also with a suiatble section of hose from a scrap car -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01635.jpg

 

Hoses clipped together to hold them in place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01636.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01637.jpg

 

Hose held roughly in place where it will join the banjo bolt -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01638.jpg

 

You can see roughly how it's going to work, I was quite happy at this point as I'd been able to sort out the water pipes just by using parts we had here and adapting them instead of buying new when there was no need to do so -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01639.jpg

 

Trial fit with the radiator again, just to see how it looks -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01640.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01641.jpg

 

Top hose from Thermostat Housing fitted and bracketed to the block to keep it clear of the throttle cable -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01642.jpg

 

And that's all the water pipes sorted apart from the banjo bolts on the turbo -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01643.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01644.jpg

 

Intercooler and Pipes as supplied with the Turbo engine, these were originally fitted to the car that the donor Turbo Engine was removed from, they might not be the prettiest but if they'll do the job then I'll tidy them up and we'll use them -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01645.jpg

 

Lower Pipe fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01646.jpg

 

Upper pipe fitted to Throttle Body -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01647.jpg

 

And fitted to Intercooler -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01648.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01649.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01650.jpg

 

Now that I know it all connects up as it should I'll be able to clean up and paint some of the metal pipework etc so that it's all ready to fit when the engine is in the car.

[blacksofstichill]

 got rid of the massive clump of connector blocks on the stereo wiring, soldered and heatshrunk the joints and retaped the loom -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01651.JPG

I still need to retape some more of the interior loom to tidy it up though -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01652.JPG

We also sourced some suitable Banjo Bolt fittings for the water feed pipes into the Turbo -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01653.JPG

Fitted to the Turbo -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01654.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01655.JPG

And the water pipes fitted to them -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01656.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01657.JPG

With the cars original Fusebox looking a bit dodgy Olly had also sent this up, a Mint Fusebox for the job. This is still to be fitted but it looks like it's never been used -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01658.JPG

Olly also had a Clutch built as a one-off for the car by CG Motorsport, we sent them the Flywheel, they refaced it, re-drilled it and built a bespoke clutch for the job onto it. Olly has the Tech Specs for the Clutch but I think the friction material is Kevlartek or something along those lines -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01659.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01660.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01661.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01662.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01663.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01664.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01665.JPG

Along with the Clutch there was another big purchase made for the Project, a new Emerald K6 ECU along with a flying loom, replacement Temperature Sensors and MAP sensor too -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01666.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01667.JPG

Can't wait to get stuck into wiring the Emerald up! If anyone else is after Emerald Management I can supply it and at discounted prices too.

Olly had also bought a reconditioned Power Steering Pump -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01668.JPG

The Original one had already been repainted and refitted a while back -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01669.JPG

So I removed it to replace it with the re-con one -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01670.JPG

Re-con Pump Painted -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01671.JPG

And fitted -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01672.JPG

Oil Filter adaptor as removed from the old engine -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01673.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01674.JPG

All cleaned up and ready to fit -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01675.JPG

Delving into the Mountune stock I fitted a new O-ring onto the bolt -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01676.JPG

Fitted onto the engine -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01677.JPG

Since the engine was ready for the Gearbox to be fitted we had taken it off the stand and moved it round to the other workshop -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01678.JPG
 

[sidrick]

Compulsive reading Great work.

[blacksofstichill]

Cheers, glad you're still finding it interesting!

[blacksofstichill]

Spacer plate fitted -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01679.JPG

Flywheel fitted -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01680.JPG

Clutch Plate Centralised on the Cover Plate -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01681.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01682.JPG

And bolted up to the flywheel -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01683.JPG

Release Bearing fitted to the gearbox -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01684.JPG

Gearbox fitted -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01685.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01686.JPG

Starter Motor Fitted -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01687.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01688.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01689.JPG

Transfer Box ready to fit -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01690.JPG

New O-ring fitted -


http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01691.JPG

Fitted to the Gearbox -


http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01692.JPG


http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01693.JPG

Oil Pressure Switch removed from the old engine -


http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01694.JPG

And fitted to the New engine -


http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01695.JPG

Old engine Mount along with new Powder coated Brace and top plate -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01696.JPG

Engine Mount cleaned up -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01697.JPG

And painted with Silver Engine Enamel -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01698.JPG

Fitted to the engine -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01699.JPG

New Oil Filter and Alternator Belt -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01700.JPG

Fitted -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01701.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01702.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01703.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01704.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01705.JPG
 

[sidrick]

I can't believe you're using that scabby alternator pully on that imaculate engine

[scottybo]

she looks just about ready to go in!

[blacksofstichill]

I can't believe you're using that scabby alternator pully on that imaculate engine

 

Ha ha!  I actually painted it but chipped it when I fitted the belt.....I hope nobody notices when it's in the engine bay!!

 

she looks just about ready to go in!

 

Almost!  new Webcon Fuel Pressure regulator to be fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01706.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01707.JPG

 

Before I fitted the engine I wanted to get the fuel pipes sorted out and fitted to the engine first rather than trying to do it once it was in the bay. Although we are using a non-standard fuel rail I wanted to be able to use the standard fittings on the car itself so it was a "plug and play" job once the engine was in. Looking at the fuel pipes on the original engine I can see what I need to replicate -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01708.JPG

 

New Length of fuel Pipe for the job -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01709.JPG

 

I need this end from the standard pipe -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01710.JPG

 

So I cut the rubber pipe off so I can re-use the end -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01711.JPG

 

Same goes for the other pipe end -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01712.JPG

 

Feed Pipe fitted to the Fuel Rail -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01713.JPG

 

Return Pipe fitted to the regulator and fed back under the plenum -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01714.JPG

 

And original pipe ends fitted to the new pipes -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01715.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01716.JPG

 

Plastic Sleeves fitted over the pipe with a clamp to hold the sleeves in place and prevent them from rubbing through -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01717.JPG

 

Next up I needed to think about the engine wiring and sensors fitted to it. The original Coil Pack/Injector loom will be revamped and fitted along with the ECU -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01718.JPG

 

Emerald supplied us with a new Air Temp Sensor to be fitted to the plenum. I knew it was a much smaller thread than standard but didn't worry about it as our plenum had already been fitted with an insert for a different sensor anyway. Here's how the sensors compared, Emerald one on the top left, Original turbo engine one on the top right, standard one from the original engine still in the Plenum -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01719.JPG

 

Trouble was, our adaptor insert in the Plenum was a different thread to the Emerald sensor and there was no way it was budging to remove it and fit another one -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01720.JPG

 

However, after measuring resistances over different temperatures on both sensors I found that the one originally in our turbo engine still worked within the same range as the emerald one so I refitted it to avoid any further Plenum Dramas. Emerald also supplied a Coolant Temp Sensor -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01721.JPG

 

This replaces the original one as shown below and left us with the same problem of having to make an adaptor, etc to suit -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01722.JPG

 

Luckily though, our Turbo engine had also originally had a different temp sensor fitted too and we still had the thermostat housing from it with the adaptor already fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01723.JPG

 

So I decided to use that housing and swap over all the sensors and thermostat over. Housing removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01724.JPG

 

Sensors swapped over -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01725.JPG

 

And re-fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01726.JPG

 

Now it was time to let the engine see some daylight before it was fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01727.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01728.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01729.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01730.JPG

 

Because I was working outside I slid a sheet of board under the car to make it easier to slide the engine under the front of the car -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01731.JPG

 

[lee grout]

Yes, that's what we like to see. 

[scottybo]

im so very excited!

[Lawrence Selly]

Can you do an all-nighter and get the floodlights out ^^ 

I can't wait for the next installment! 

[tomsy]

A video of the engine running would be awesome.

[dalelc16]

Really is a top job.

Fancy moving down to plymouth and helping with my engine

[blacksofstichill]

Yes, that's what we like to see. 

 

Cheers! 

 

im so very excited!

 

It's been a long wait eh?!

 

Can you do an all-nighter and get the floodlights out ^^ 

 

I can't wait for the next installment! 

 

 

It wouldn't be the first time I'd worked late into the night, next instalment below for you!

 

A video of the engine running would be awesome.

 

I'll definitely get one uploaded once it's running, cheers!

 

Really is a top job.

Fancy moving down to plymouth and helping with my engine

 

Thanks!  I think my wife and kids might object to me moving away!  Any advice you need at all along the way though just drop me a PM and I'll be happy to help, cheers!

 

One last thing to be fitted before the engine goes in, a new fuel filter -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01732.JPG

 

The bolt for the clamp broke but I'll fit another one when I'm working on the car another day -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01733.JPG

 

Front end of the car up in the air -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01734.JPG

 

Engine and box slid under the crossmember -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01735.JPG

 

Normally I would lower the car body back down a bit but I had plenty of height to work with on the engine crane so I lifted the engine up to meet the body and got it onto it's mounts -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01736.JPG

 

In typical fashion, the stud on the rear gearbox mount sheared off before the nut was tight so I'll have to swap that over with another one but that's not too bad to do thankfully. It's great to see this finally making it into the engine bay -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01737.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01738.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01739.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01740.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01741.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01742.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01743.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01744.JPG

 

With a little bit of time to spare I finished off the retaping of the loom inside the car -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01745.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01746.JPG

 

[lee grout]

Great update and pics. Will the space you've got left be enough for the fan/radiator and intercooler?  The turbo takes up a decent chunk of space which looks right in the way lol.