Sierra 4x4 16V N/A
28-08-2009, 02:09 PM
#1
Virgin
Thread Starter
Join Date: Dec 2005
Location: Warsaw, Poland
Posts: 7
Likes: 0
Received 0 Likes
on
0 Posts
Sierra 4x4 16V N/A
Hi there guys!
I would like to share my Sierra 4x4 project with you guys, seeing how many fine cars are over here.
It started as a stock 2.0 DOHC 8V 4x4 sierra bought from some farmer. The car was is a really bad condition but the shell, engine and transmission was ok.
I treated this build as a way to gather experience and i let my imagination run wild. Buying a Cosworth engine is way out of my budget, but the RS 2000 16V 150bhp engine is scrap cheap in Poland, fits the stock DOHC oil sump and is really tough.
The head received mild porting, a 3 angle grind on the seats, 2 angle grind on the valves, chambers were matched and the compression ratio sligthly increased. New guides, seals etc also were installed.
Bottom end fully rebuilt using lighter pistons, new bearings, seals etc.
I decided to make a new inlet and exhaust manifold to gain more power from the engine:
A custom made first pulse exhaust manifold. Each runner is build within 5mm lenght. The idea behind this manifold is to utilize the first 3 exhaust gas resonance pulses. Normally most cars have exhaust manifolds tuned to have the second pulse coming at high revs and third pulse at middle revs. If the first pulse is 100%, the second one is about 30% weaker, the third one is again 30% weaker than the second one. 4th and 5th are so weak they hardly count. In my manifold the first pulse which is the strongest came at ~7000rpm according to calculations, the second at 3500rpm and the third at 1750 rpm. This is serious racing technology, normally you have to pay big bucks for a proper manifold like this, its a nice thing to be egg headed and have craftsman skills
Now on to the intake side. First of all, the head was port matched with the custom made intake manifold adapter, the ports severely straightened to reduce flow losses, the ports cross space was carefully calculated and machined to the results.
The manifold adapter.
The intake ports. You can see how much the ports are straightened, at stock the bend was about 70 degrees.
Because the engine was intended for trackdays, rally etc. i had to have excelent throttle response and power control, the only thing capable of giving me that were individual throttle bodies:
They were sourced from a Suzuki GSXR 750 bike and machined to a proper diameter.
Installed in the car.
The air filter adapter, horns, also from the GSXR.
Normally most people would stop here, but having the knowledge and the xtreme mental illness i decided to take this one step further. If i have a racing exhaust manifold, the inlet is also intended for racing, why not make it better ? I knew one trick to get more top end power, using staged injection. Thats it! Ok, back to the hacksaw and hammer!
Thats this ? Is this a second set of injectors sitting on the trumpets inlet side ?
Yes it is ! Now lets see how do they look like when working !
I really love the pictures in high resolution, the droplets of fuel are hypnotizing !
For your viewing pleasure, a video showing how the injectors work. For the need of this movie the engine was set up to run on them. Because of safety reasons and engine characteristics these injectors work only above 4500 rpm and at 30% throttle.
Assembled and ready for mapping. I used a megasquirt stand alone and mapped it myself.
The suspension:
I used wishbones from a Scorpio and fabricated a new rear beam for them. 20mm rear sway bar, 28mm front cosworth sway bar, custom made front suspension (the stock sierra assembly is so worthless...), KYB dampers, cosworth spec springs and polybushes everywhere.
Unfortunately i have only one crappy video of the car on the road:
http://www.youtube.com/watch?v=lByVWGipGWE
You can hear the ITB in front of the car and the exhaust on the back. My friend miss shifted the third gear.
The new owner having fun:
http://www.youtube.com/watch?v=FfIc76gdx0E
The car ran about 6-6.5s 0-100km/h depending on the start and gear changes.
Feel free to ask any questions, i have a lot more pictures of this build.
Btw: a new project im working on:
I would like to share my Sierra 4x4 project with you guys, seeing how many fine cars are over here.
It started as a stock 2.0 DOHC 8V 4x4 sierra bought from some farmer. The car was is a really bad condition but the shell, engine and transmission was ok.
I treated this build as a way to gather experience and i let my imagination run wild. Buying a Cosworth engine is way out of my budget, but the RS 2000 16V 150bhp engine is scrap cheap in Poland, fits the stock DOHC oil sump and is really tough.
The head received mild porting, a 3 angle grind on the seats, 2 angle grind on the valves, chambers were matched and the compression ratio sligthly increased. New guides, seals etc also were installed.
Bottom end fully rebuilt using lighter pistons, new bearings, seals etc.
I decided to make a new inlet and exhaust manifold to gain more power from the engine:
A custom made first pulse exhaust manifold. Each runner is build within 5mm lenght. The idea behind this manifold is to utilize the first 3 exhaust gas resonance pulses. Normally most cars have exhaust manifolds tuned to have the second pulse coming at high revs and third pulse at middle revs. If the first pulse is 100%, the second one is about 30% weaker, the third one is again 30% weaker than the second one. 4th and 5th are so weak they hardly count. In my manifold the first pulse which is the strongest came at ~7000rpm according to calculations, the second at 3500rpm and the third at 1750 rpm. This is serious racing technology, normally you have to pay big bucks for a proper manifold like this, its a nice thing to be egg headed and have craftsman skills
Now on to the intake side. First of all, the head was port matched with the custom made intake manifold adapter, the ports severely straightened to reduce flow losses, the ports cross space was carefully calculated and machined to the results.
The manifold adapter.
The intake ports. You can see how much the ports are straightened, at stock the bend was about 70 degrees.
Because the engine was intended for trackdays, rally etc. i had to have excelent throttle response and power control, the only thing capable of giving me that were individual throttle bodies:
They were sourced from a Suzuki GSXR 750 bike and machined to a proper diameter.
Installed in the car.
The air filter adapter, horns, also from the GSXR.
Normally most people would stop here, but having the knowledge and the xtreme mental illness i decided to take this one step further. If i have a racing exhaust manifold, the inlet is also intended for racing, why not make it better ? I knew one trick to get more top end power, using staged injection. Thats it! Ok, back to the hacksaw and hammer!
Thats this ? Is this a second set of injectors sitting on the trumpets inlet side ?
Yes it is ! Now lets see how do they look like when working !
I really love the pictures in high resolution, the droplets of fuel are hypnotizing !
For your viewing pleasure, a video showing how the injectors work. For the need of this movie the engine was set up to run on them. Because of safety reasons and engine characteristics these injectors work only above 4500 rpm and at 30% throttle.
Assembled and ready for mapping. I used a megasquirt stand alone and mapped it myself.
The suspension:
I used wishbones from a Scorpio and fabricated a new rear beam for them. 20mm rear sway bar, 28mm front cosworth sway bar, custom made front suspension (the stock sierra assembly is so worthless...), KYB dampers, cosworth spec springs and polybushes everywhere.
Unfortunately i have only one crappy video of the car on the road:
http://www.youtube.com/watch?v=lByVWGipGWE
You can hear the ITB in front of the car and the exhaust on the back. My friend miss shifted the third gear.
The new owner having fun:
http://www.youtube.com/watch?v=FfIc76gdx0E
The car ran about 6-6.5s 0-100km/h depending on the start and gear changes.
Feel free to ask any questions, i have a lot more pictures of this build.
Btw: a new project im working on:
28-08-2009, 04:18 PM
#2
Lucifer II - 666
I think thats fantastic for a budget build engine and t/b's
well done!!
well done!!
Nice to see an I4 being worked on 
Thread
Thread Starter
Forum
Replies
Last Post
Adam Graham
Restorations, Rebuilds & Projects.
7
06-09-2015 06:04 AM
