After running the engine is carefully, it was given an oil and filter change and cylinder leakage test.

The next procedure was to calibrate the Autronic SM4 on the Rototest chassis dyno for ECU mapping.

In a departure from conventional “chipping” methodologies that most Tuners tend to use, we quickly identified the Autronics stand alone ECU as being a suitable solution four our purposes.

The Autornic SM4 is highly regarded in the world of professional motorsport as being a very capable and robust ECU solution with the following features:

• Sequential fuel injector control at speeds of up to 30,000rpm
• Comprehensive speed density load sensing, along with exhaust manifold pressure sensing to calculate the true delta pressure accross the cylinder head, enabling very fast and accurate digital assessment of fuel and ignition under dynamic conditions.
• Excellent peak and hold control of low impedence injectors.
• Fully sequential ignition control (cylinder by cylinder compensation).
• Closed loop wide band lambda feedback with 3D target tables.
• Exhaust gas temperature monitoring with closed loop feedback control.
• Closed loop boost control with 3D target tables.
• Traction control
• Launch control
• Over-run boost enhancement (anti-lag).

Here are some pictures of the uprated Escort Cosworth engine fitted:

The HKS SSQV dump valve is probably the best type available. HKS do not offer a dump valve kit specifically suited to the Escort Cosworth so we manufactured our own installation components.

Here is the special SSQV flange welded onto the intercooler pipe:

Here is the HKS SSQV dump valve fitted to the Escort RS Cosworth:

Here is the uprated Escort Cosworth engine being re-fitted into the car.

Traditionally, most uprated clutches for the Escort Cosworth tend to be either a heavy duty organic or sintered menatl friction plate coupled to a clutch cover with a heavier clamping force.

The organic lined friction plates are easier to drive and feel more like a standard clutch but are compromised by their relatively low torque holding capacity. The sintered metal friction plate has a significantly higher torque holding capacity but is compromised by it’s aggressive engagement, judder and noise. In both cases, the uprated clutch cover springs provide a heavier feel to the clutch pedal.

A solution to the above issues is the use of the HKS GD Max multi plate clutch and light weight flwheel. The twin friction plates are sintered metal to provide maximum torque handling capacity and are engaged synchronously to provide a smooth operation. The doubling of friction material quantity reduces the need for heavy pressure plate springs, so the overall feel of the clutch is light, progressive and easy to use.

The problem is that HKS do not make a twin plate clutch kit for the Escort RS Cosworth so we had to engineer a kit from a Japanese engine to fit and work correctly.

This is the HKS GD Max twin plate clutch kit:

The standard flywheel was engineered to accept the HKS GD Max clutch kit:

One of the engineering challenges to over come was to convert the stardard “push” type engagement to a “pull” type and become hydraulically operated:

We think that this is the first time in the world that the HKS GD Max twin plate clutch has been successfully installed in an Escort RS Cosworth.

In operation, we can report that the clutch biting point is exceptionally smooth and light. Mission accomplished!