Bought this 90 spec S2 about 18 months ago now, it was alright, I figured I'd just freshen the engine up and pass it on. Well a quote for £650 to recon the bottom end put that plan in the bin!!

I got a 2.0 bottom end from Ford (new) for £340, sump, head gasket and a few bits and I was off...

S2 had a cam in the head so that was kept but fitted into a rebuilt XR2i head along with its twin springs. Inlet ports were opened to match the gasket and so was the inlet manifold.

I made the water pump and breather plate, drilled the flywheel, blocked the block, all the usual zvh items.

Cossie management was used as I thought the MFI system might be a problem on the engine, i also thought it would give better value to the car. A 2wd loom, ecu, ISCV, throttle body, TPS were bought for £300. The yellows, EFI manifold, head, fuel rail, MAP sensor, stg1 chip were all left overs so 'free'.

I removed all the 'engine' from the loom ready to install the cossie parts.

I also had 2wd front&rear calipers so a brake conversion seemed logical! Rally design supplied the disks and Nath the rear brackets. I made the hoses to the right lenth.

Everything was removed from the bottom of the car and it was cleaned and painted in stone chip. All the suspension blasted and painted, poly bushed and refitted.

I have done everything I can to increase the value of the car for minimal outlay, this is truly DIY on the cheap! It might be the long way about it but who cares!!

So far I have got the engine as you see in the pics, vertually ready to go in!

I don't car its not chromed or running ally tanks etc have a look and comment if you feel fit.

Cossie 4 pots


Bin the ABS, repipe


Twin 2wd intercooler


Complete 2.0ZVH


I will push it out at the weekend and take some better pics if anyone is interested.

 

looks well mate, so how much has it cost you in total and how long has it taken to get to this stage if you dont mind me asking?

Danny

 

So far I have taken about 6 months, but I don't get much time on it. The car was sat for about a year before i got into it.

Took 2 weeks of spare time at work to do the underside. Putting the engine together was quite quick once I got on with it.

Basically 2 steps forward, 1 back. Once you modify one thing it changes how another fits and works.

Intercooler £85
Engine £700 total
Management £250
Wheels £100
Underside £100
Brakes £150
Clutch £200

It does help I have a precision engineer next door, a sandblaster and an ally welder as customers and a lot of customers who have stuff lying about!

 

Good luck to ya , looks like your building just what you want to have some fun.

Colin.

 

I'm very impressed with your work and hope to see more from you soon.
I wanted cosworth mangement but i 'll take 1 step at a time.

Thanks for the post

 

I figure if you don't try, you never find out.

Egliptor; shop through the for sale sections and there is loads of bits out there.

Try RSOC, turbosport, PF, find it, Ebay.

Stuff is out there cheap, you just have to look about and not get your arse slapped.

I payed £80 for loom, £20 dizzy, £45 throttle body and sensors, £60 for L6 ecu.

Get a complete head from an Xr2i and you get all the manifolds and you don't need an adaptor plate, just swap all the valves over. Its not expensive.

As you can see I have not had it running yet so lets not take it as a runner, but it should!

 

That is seriously good going, 250 for the management is a real achievment aswell. I'm gonna start sourcing the bits soon myself, I was hoping to get it all for around £700.00 but you've made me think again.

Look forward to seeing it running and on the rollers. Just goes to show how much money I could of saved with a little know how and time.#

Good work

 

I have no idea if it will fire up yet so hold on!!

I have to sort out a chip, the one I have is just for a stage 1 sapph. It might run on it but I doubt it will very well.

I also take the piss with my machine shop, there is plenty to modify! I'll try and post some pics later to show you whats needed so far.

I am sure there will be many hurdles to cross in the future before I can turn the key.

I got the EFI head, manifold, fuel rail, injectors, 2 bar map, stage 1 chip, crank pulley, crank sensor, and one intercooler for free so please don'tr think its that easy! I can also get 20% discount on Ford parts which helps.

If you ask someone like Yodi or Spadge for prices on the cossie stuff you might get a deal. ML developments were cheap too but very slow.

 

well done looks good

yeah i have dealing with ML they are good but are slow lol+

 

Engine and gearbox are now in.

Radiator and Intercooler mounted, just need to do the plumbing next before the wiring. Notice where I have welded up some holes in the manifold and modified the inlet to mount the cossie throttle body.


Photo of the oil return pipe going into the sump, will use Samco to link to the turbo due to difference in pipe size. 13mm to 17mm.


Her is a pic of the throttle bracket. I was just mucking about seeing how to get the cable on. Noticed if I removed the bracket and bolted it to the rocker cover it lined up ok. Don't know if I will get WOT but I'll find out. I need to trim the bracket along the white line for bonnet clearence and brace it under the intake clip. But it looks promising.



Here is the other side of the inlet manifold modified to accept the air sensor from the cosworth and the blocked off cross over pipe.



Here you can see the modified lower pulley fitted and you can see the clearence problems if you don't!



Her is the firing ring from the back of the lower pulley with all but 4 teeth removed. Its important that they are at 90' to each other.



Here is the trimmed lower pulley.



So far thats it. I now need Samco's from Rally Design to make the intercooler fit onto the engine and turbo. Once thats done its time to make a breather, sod Bailey stuff I'm on a budget!! I'll make it!

 

Samco is on order from Rally Design, so I got on with the wiring.

WHAT A MARE!

Thankfully I found a 2wd loom diagram on the web ( www.derbyshire-rsoc.co.uk/cosworthmanuals/ ) which shows me all the colour codes.

So now I am going to lay out the loom, grab a bottle of Tip-ex and label every plug!!

Then, next, its a hybrid dizzy.

 

looks smart

 

any updates ?

 

Just got back from Orlando, give us a chance!!

 

 

Only thing I have done this week is install the intercooler hoses. Just waiting on Ford to deliver my top hose than I can get that on.

Sorry for the picture quality, I'll try and get some better ones ASAP.





Now i have the front in the air I could finnish the brakes off and get the rims on.

Getting there slowly.

 

Slowy but surely getting there

 

ZOO do hybrid dizzys if I recall correctly.....

 

 

Well impressed with that!

 

Looking good when you hoping to get it on the road?

 

'might' try getting it running middle of Feb. Wife's away.

Not going to ZOO, I want to do as much as I can myself, that way I might learn something!

 

done a little more now.





Thats the cowel panel replaced, not a bad job, took a couple of hours.





repairing the wings, I think a gerage door must have dented them at some point. Just tapped the dent out and finninshed the shape with Plastic padding.



Cossie breather pot (had it lying about) fits well here and is out the way. Will secure pipes so the belt is not fowled.



Quick mock up of the front bumper. I will finish the opening off soon. But it all looks good so far!



Could not resist this! late escos 200 block, no rear core plug version, £400! complete with windage tray and 1 dead piston. Going to send it to Julian Godfrey for repair and long studding. Should be bomb proof when done!

 

Top stuff mate.

Looks like you also found that the 1800 seriias "cambelt cover" bracket that holds the CPS doesnt fit the Zetec block, lol...mare! I take it you used one side and its working ok??

 

No I just chopped it about and had it re-welded and she is sweet.

Not running yet, still need to modify dizzy. How did you do yours? weld two together or bastardize one into the other?

Am going to decorate house rather than get car running as I am more likely to get a blow job fromthe wife for the former than the latter.

Sad I know.

 

Im running a coilpack

 

how do you do that? I am running cossie management, so is it loads of work extra?
Or do I just continue on with the hybrid dizzy idea?

 

Got 90% of the dizzy done.

Cost £20 so far

Just need to mount the phase sensor and the ERST drive flange and we should be done.

I'll sort some pics out soon.

 

After dismantling the cossie and escort dizzys you keep the ERST housing, cossie shaft, phase sensor, and the ERST washers.

We figured 16+mm had to be lost in the top half of the cossie shaft to fit under the ERST cap. It might have been more possibly nearer to 20mm.

So we put the shaft into a lathe and turned the coller under the phase trigger down, leaving a coller for it to seperate the washer from the trigger. This could have been 1mm less but the lathe was old and tools shite. (no CNC for this project!)

we then machined 6+mm off the rotor mount, recutting the slot and sanded the base of the rotor down for it to sit lower on the shaft.

The bottom of the shaft was cut off for the ERST drive plate to sit up onto.

Next we have to make a 4mm thick plate for the phase sensor to sit on. Counter sunk holes will be drilled into it to allow fitting to the ERST housing. Tapped holes into the plate for the phase sensor to be fitted onto.

It looked a mare but was quite simple when we got into it!

Completed photos next week with some luck.



Modified shaft.



Shortened rotor. Should make future servicing interesting!!

 

Now I have made an adaptor disk.

4mm thick, 59mm across and 24mm hole. this is screwed into the ERST dizzy and the cossie phase sensor sits on top. Holes still need to be counter sunk as the phase sensor sits on top of one hole.



So far fairly simple stuff, just need to call PJ and get a new sensor.

 

Top stuff mate.

 

keep the updates coming this is really intresting as i perfer the diy side it will also help others in the coming future and we can all do it for cost

 

I'll need to test pilot this when its done l

 

you better be quick as I have someone who wants it already.

 

very nice! Good value too. You sorted out who's mappng it yet?

 

I was thinking about Engine Advantages. Not really too sure yet.

 

hi mate just wondered what sort of oil pressure you was getting im getting about 1.8 bar @3000 rpm is this about right?

 

still only half way through the dizzy build so she's not a runner yet.

not got a pressure gauge either!