We are using a stand alone fully programmable ECU solution to control this engine, which enable us to discard the standard ignition system and employ direct fire ignition coil packs.

Direct fire ignition coil packs installed:

The standard Escort Cosworth inlet manifold is compromised for high power applications, so we installed a specially manufactured high volume plenum.

In the Escort Cosworth tuning world there seems to be a trend towards replacing the 4WD standard exhaust manifold with the 2WD exhaust manifold, so we evaluated both for air flow efficiency on our Superflow air flow test bench.

The 2 wheel drive Sierra Cosworth manifold is a two piece casting which has a change in direction of almost 180 degrees, so we were not surprised to see that the shorter and straighter Escort Cosworth 4 wheel drive manifold has significantly higher air flow volume.  We did not undertake any calculations to estimate any differences based around exhaust gas harmonics, but we selected the less efficient 2WD manifold because of the packing concerns of our intentions to experiment with a new design of turbocharger at a later date.

After machining, the following processes are applied: measure cylnder bore size, ovality and taper to ensure that the boring has been carried out correctly, measure and correct piston ring clearances, measure piston to cylinder clearances, measure and correct crankshaft end float, main bearing and connecting rod bearing clearances, measure deck to piston heights, measure and balance combustion volumes.

Crankshaft in position with assembly lube and heavy duty main bearing cap studs:

Crankshaft installed:

Pistons and heavy duty head studs installed:

Cylinder block assembly completed and sump installed:

The cylinder head is fully assembled with valve springs and adjustable pulleys:

Clinder head camshafts installed:

Final engine assembly with some auxiliary components:

The Escort Cosworth YB cylinder block is the next component to be processed.

Firstly it is de-greased and receives a chemical wash.

The next process is to assemble a deck plate so that the cylinders can be bored and honed. The theory behind this process is that when the cylinder head is unbolted from the cylinder block, the cylinder block deforms slighty. If the cylinder block is bored and honed in a deformed state, the cylinders will go out of shape when the cylinder head is re-fitted. Boring the cylinders while a deck plate is torqued onto it ensures bore conformity in service.

The YB cylinder block is then processed to machine for heavy duty cylinder head studs and head gasket O rings.

The Escort Cosworth cylinder head exhaust ports were significantly enlarged and straightened to yield a substantial 50% increase in air flow compared to the cylinder head.

This increase will enhance volumetric efficiency and lower the cumbustion temperatures.

This picture shows the raw finish just after hand grinding, the finish is subsequently cleaned and smoothed.