Iam sure there was a bloke from the midlands who purchased all the spares from m sport as I spoke to him about exhaust manifold years ago , can't remember if ian gave me his number or if it was someone else but he had lots of stuff and he was asking a lot of money for the parts. There's some bits come up on ebay in the last few weeks could be him so worth contacting.
All I know it had
CGI block with liners and all bits machined away to make it as light as possible
Uprated head
Custom dry sump system mounted to the rear as the engine was titled back
Custom inlet manifold
Revised water pump with larger outlet
Custom exhaust manifold with custom exhaust flange adaptor spacer to run egr
Custom turbo and titanium wastegate which I believe are around Ł2500 alone just for wastegate.
All the radiators etc should be the least of your worries as you can have very good copies made and it would not matter as long as you get the look .
I know they were titled forwards so they caught a lot more air instead of being mounted straight

Hope this helps

Cheers paul

 

Cheers for the info mate.
It was mainly the correct rods, pistons and possibly crank I was after as it would be nice to have the correct internals, and the exhaust manifold would be nice to compliment the rest.
I have contacted the chap on eBay. He says he purchased all of Cosworth’ NOS YC parts recently. He has some nice bits, but a lot of it isn’t really what I’m after. Alrhough he does have the billet coil on plug cover, alloy valve spring retainers and thermostat take off which would be nice.
Any fabrication work isn’t inmportant as I work at AHFabrications as a Motorsport fabricator, it was more to look at how they had done various things more out of interest than anything. My rad is going in the boot.
The engine is going into my Escort so I’m not making some full replica anyway. We’ve just agreed that the correct rods, pistons and crank would be nice to use.
Try and cant the engine back in the bay as it has dry sump.

 

From what I can gather, the first engines were built by Mountune for Ford in 1998 and they were an unlinered CGI block and ran Mahle pistons and rods with their inlet manifold.
In the mean time, Ford bought Cosworth and moved the operation in house in late 1999. They need more power, torque and reliability so started from scratch with the engine, although the cross over period of 2000 the engines remained very similar with a Mountune still supplying parts.
Cosworth then machined all the blocks, linered them with their own pistons, rods and crank and later revised the inlet manifold. Then other various changes came through as the program went on.

 

Personally I think all the later engine internals would be made in house by cosworth them selves and you would pay a premium for genuine parts even if you could get them which to be fare you never really see for sale.
Just build it to a good spec and you will be fine , if you've got a few grand to throw at it then buy a arrows crank , rods ,and some cp Pistons with some billet mains caps would make a super strong engine.
As for the head just a nice CNC head with oversized valves would be fine.
Turbo would cost a bit as it would need to have a Maram shaft for antilag .
Wastegate would cost a fortune so just use a tial etc.

Cheers paul

 

Keep your eyes on eBay Murray. I've seen a few of the exhaust manifolds come up for sale. Maybe talk to nortech or Garry at GR Performance to make you a replica with a more useful flange on.
Buying a focus now?

 

I could build a manifold at work, no problem. It would just be nice to have a genuine part to compliment the Inlet manifold etc. Keeping an eye on eBay too.

Like I said, won’t be a replica of anything, it’s more to satisfy my own interest if anyone has pics and what available parts I can find to make the engine actually mean something, rather than a just another Zetec turbo.

 

Head wise I’m sorted. I have one of the early developmental head castings with the huge inlet ports and valves. 33.5inlet and 30mm Ex valves off he top of my head and 66mm inlet ports

 

Cylinder head tappet bores machined to large diameter so the cam rode onto the sooner, DLC coated tappets, hollow steel billet DLC coated cams, at early stages used 9/32 valve stem with BDG spring retainers, spring platforms with Cosworth BDG/DFV Schmitthelm valves springs, Nimonic exhaust valves Mahle Motorsport pistons, Arrow Precision did the crank and rods at some point (when they had no flywheel), Primary Designs Inconel manifold, custom waste gate similar to the version used on the rallycross cars.

 

Some good info there. Thanks.

 

I have a contact who can supply genuine camshafts if your interested, all the way up to complete engine which there are 3 available. Not cheap though im afraid. I recently had one of those mountune inlets but sold it and went for a Cosworth wrc one instead (same as on your 4th picture).

Do you have any more info on the head you are using?

Thanks

Dave

 

Originally built by Montune in 1999, the YC Zetec engine is a turbocharged (with no street equivalent) version of the Ford Zetec E 16V engine. Cosworth took over the engineering and production of the YC Zetec in 2000.

Many interesting features are included in the new unit. To improve weight distribution and air intake conditions the engine is inclined by 25° to the rear as compared to the street versions of the Focus.

The turbocharger used is a TR30R Garrett AiResearch unit which was developed specifically for the WRC Focus. The TR30R is a race derivative of the "old" Garrett T3 turbocharger but uses an extremely expensive Mar-M 247 (this nickel-based super alloy is a trademark of Martin Marietta Corporation which became part of Lockheed Martin Inc. in 1995) turbine wheel instead of the INCONEL alloy turbine of its predecessor and has revised geometry to better accommodate the 34mm intake restrictor. All turbo calculations and dimensioning were done with an integrated 34mm restrictor as specified in FIA regulations.

 

The engine block used in the WRC Focus was manufactured using CGI, compacted graphite iron, instead of standard grey iron to provide a stronger lighter engine block. There are several noticeable differences in the block when compared to a stock Zetec or even the Cosworth CGI engine block.

The most noticeable difference is the extended cylinder liners requiring the use of a special aluminum alloy block adapter to provide sealing to the cylinder head.





Additional changes were made to the YC block such as the lack of an oil filter mounting boss. This was done as the engine was not intended to use a conventional wet sump oiling system. The engine was designed with a special front cover seal the front of the block.





A tear drop shaped water inlet requiring a special water pump housing.





The removal of common mounting bosses used for the AC brackets and other accessories.





The gear box mounting points were also changed. The removal of the lower right mounting arm presents its own challenges. It would also be good to note that the rear main seal retainer bolts are 6mm instead of the standard 8mm. These can be drilled out and an 8mm Heil-coil installed to accept a standard rear main seal retainer.

 

The YC Zetec has used several design crankshafts from 1999 to 2003. None of them are compatible with aftermarket pistons and or connecting rod sets. They were designed and manufactured to be used with the WRC YC extended liner block, piston and connecting rod set. Two of the know variants are shown here one with lightened counterweights and one without counterweights.

 

The pistons and connecting rods used in the YC Zetec were engineered and supplied by Cosworth UK. The pistons are manufactured from proprietary alloy called designated by Cosworth as COS AL 010, utilize an green anti-scuff skirt coating and a 84.8 mm bore size. It would be good to note that the pistons utilize a larger 22mm piston pin and will not fit a stock or even aftermarket performance connecting rod. They where designed to be used exclusively with the Cosworth YC long connecting rods.





The rods themselves where manufactured for Cosworth by Pankl Racing of Austria. They weigh in at 268 grams much lighter than the 535 grams of a stock connecting rod and are substantially longer to accommodate the extended cylinder liners of the YC CGI engine block. Again this rods will not work with any other piston besides the YC piston used in the WRC Focus.

 

The YC Zetec water pump is only different as far as the water pump impeller is concerned. It uses a aluminum allow impeller as the factory Ford water pump impeller was plastic. It would be good to note they also changed the fin design.

 

When building a YC Zetec it is important to use the correct water pump housing. The YC housing uses a tear dropped water inlet instead of the standard round inlet.





The YC inlet housing also has a larger inlet tube that when used with the YC water pump and housing increases coolant flow by a 50%. This was done to address the overheating issues the original Montune WRC Zetec encountered.





The housing was also milled to remove unnecessary material to save weight on the original rally car.

 

all crap i had saved on my pc from years ago

 

All good stuff though!

 

It's only crap if it's of no interest to anyone.


Your post appears to be very interesting, even to those not intending to ever build or own a YC.

 

 

What an engine ..good luck mate.

 

A friend of mine wants to sell a waterpump housing with Pump. Exactly like that. What is it worth? New old stock. Never been used.

 

any pics? the standard ford ones look very similar and are worth very little, but if it has the teardrop shaped hole and has been lightened, then it will probably be worth a bit more

 

this is the waterpump

 

I have a question.
is this a Cosworth inlet Plenum for the Zetec YC engine. It is adaptable to every throttle body system. My friend bought a convolute of Ford parts and we do not know exactly what it is. It seems to be a rare item

 

Ian Howell supplied me many years ago a wrc water pump, only mine had not had the excess material removed so possibly worth contacting him to see if he’s still got a contact that can get them?

 

thank you. I do not want to have one. We have! But we do not know what it would be worth when selling