I'm now ready to use my mk1 focus rs engine in a sierra. Due to health and family commitments it has lay many years but I'm now ready.
I want to keep price down and source used parts were possible.
I dont really have a BHP that I need but I'm guessing if its 300bhp it will keeps cost down a bit.
Some help is needed to help me understand what I need.
Can I use the mk1 frs flywheel and clutch? The clutch should be OK up to 300 bhp
is the mt75 the best gearbox for this engine and what modifications is needed?
Can I use the mk1 frs exhaust manifold or does the turbo need to go on top?
Would a used 4x4 intercooler be the cheapest option? Its suitable for up to 300bhp as well?
what bore of an exhaust is needed? Just any cosworth exhaust?
Can I use the mk1frs inlet and injectors?
Does 1.8 cvh engine mounts fit both sides?
Does a standard sierra radiator need upgrading to cosworth?
I'm on a budget but I want it to be professional.
I've read many questions asked but none that answer my questions properly?

 

for a nice neat install you will need sump and oil pipe up. also water rail. and water pump runs backwards so need kit to drive it the right way around etc. exhaust 2.5" to 3" bore would be ok for it and alloy upgrade cvh rad should be fine

 

Gearbox.
Good gearbox, crap first gear ratio.

Yep your flywheel is fine. Most prefer a lightweight one but the standard Rs/ Zetec one is fine.
Clutch, yep the Frs Ap racing clutch is ideal.
Mods for this to work. A longer clutch pivot pin from Gbs/kitspares around Ł20 or Westfield made a thrust bearing spacer at around ~Ł100. This is because there is a 20mm shortfall. Finally you want a spigot bearing ~Ł10.
Only the top five bolts connect to the engine, this is fine. There is a big chunk of alloy on the bottom of the bellhousing that I shave down in a kitcar. You may not need to in the Sierra.

Engine,
Sump, you have options here but I am not a fan of the 30 year old cvh sump. Best avoided. They absolutely worship a guy called Neil Dunne on Fb and in the banger racing world.

Engine mounts, I buy laser cut plates and make my own. There are ways to use cvh.

Water pump, There is no factory reverse pump for a Rs/Blacktop like there is a silvertop but there is an aftermarket one see Ike engineering or most just run an idler See Da Engineering or Retroford amongst others.

Water rail,
I am not a fan but you won’t have much choice in the Sierra. If you fancy the raceline one do your home work. I’ve tried one twice and could not get it work well. Besides it’s unlikley to fit with a turbo (top mount).

Turbo,
your very unlikley to get one on the standard manifold between the engine and chassis leg. It’s going to have to be a top mount.
On a budget, a chopped about ford Zetec manifold works nicely upto and around your target power.

Inlet, if you can clear the steering and chassis leg the Rs one will work nicely. I chopped the elbow of and blobbed a new one on forward facing. Injectors are 440cc and will just about run to 300bhp according to Sabre tuning .

Exhaust, I run 2.5” but will up it to 3” for 300bhp.

Engine managment, I even use the Focus Rs.

 

 

That has to be an absolute rocket ship.

 

wow thanks for all the helpful advice. What is wrong with first gear? Is it geared too high?
Its for a road car, so it might not matter as much.
Again thanks again for taking the time for such a detailed reply of contacts etc.
I'm sure ill be in touch with you again.

 

Have been planning something similar and have been collecting parts for ages, will be starting in a couple of months.

The sump will need to be replaced and an oil return fitted, a water rail is also required.
The cvh engine mounts fit ok on 1 side the other only 1 bolt lines up so a plate is required.
As far as I can tell but have not confirmed the inlet manifold, alternator and exhaust all foul on the mounts. I have bought the plenum from Kit spares which uses the sandwich plate made from an inlet manifold so the injectors etc can be used.
A return is required for the fuel tank and a fuel pump if the sierra is not fuel injected already

Now to the drive... I was led to believe that the mt75 gearbox will only have space for a 220mm clutch unless you swap the front half from a Cosworth 4x4 box, the flywheel even if it would fit will need to be drilled and a rwd clutch fitted, not sure if you can get a 220mm clutch to hold the power, really a Cosworth 240mm clutch is the one to use. A T5 gearbox would probably be the better option

The standard Ford ecu could be used if very little is changed but sorting the dash out could be trouble

Found the inlet/outlet on the standard rad were the wrong way round so bought a Cosworth item to make the pluming easier

 

Having read big wasa's reply the water rail to use is the one from Ike engineering as it goes down the inlet side, hope its good as I bought one, will find out soon

 

Mt75 takes the 240mm clutch just fine. Both a standard 2.0 Zetec and the Focus Rs.

The ecu does not require the dash.

There have been some reports of the Gbs plenum spliting under boost. I do have one as well.

 

 

yeh it’s a bit leary, needs dry roads and better tyres.

 

Clutch pin to use fwd clutch

https://www.ebay.co.uk/itm/MT75-Clut...AAAOSwbsBXiPsu

 

First gear comment is based on a 600kg kitcar and is probably unfair for a Sierra that is designed to tow a Caravan and three kids up a big hill.