RS500 Power Increases

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RS 500 POWER INCREASES
The original Sierra Cosworth engine was conceived to give around 370 BHP in Group A trim, by 1987 however, more power was required. For circuit racing use, an evolution model is allowed to be homologated with certain detail improvements, and this need have a production run of only 500 models (10% of the original).
The RS 500 engine specification was decided upon after consultation with the Touring Car teams who were racing Group A Cosworths. Amongst their requirements were a larger turbocharger and intake assembly, the facility to use two injectors per cylinder, and a massive air to air intercooler. Numerous detail improvements were also included to aid reliability; a unique, strengthened cylinder block, improved oil pump and cylinder head casting were included, as were improvements to the cooling system of the engine. This created an engine that was able to produce in excess of 500 BHP in Group A trim, and a road car giving only 17 BHP more than the standard two wheel drive version. Due to the large turbocharger used, the RS 500 was not so impressive in standard form, with no appreciable turbo boost below 4500 rpm, and a noticeable increase in turbo lag, it was far more difficult to drive quickly on the road.
Our own RS 500 Touring Car engines produced in excess of 540 BHP. The mechanical specification included high lift, long duration camshafts with solid tappets, cylinder head porting to our exact specifications, low compression pistons, and many of the other specialist engine components that are shown in this brochure. The turbocharger also received further attention, with a screwed thrust bearing, and a the turbine shaft assembly was the same as used by Cosworth in their Formula 1 Turbo engines. These cars also used a ZYTEK engine management system, which entailed the use of many special engine mounted sensors, a unique engine wiring loom, and special fuel injection parts. We have built a couple of road cars for overseas customers with this engine specification, but due to the high number of specialist parts required, this does prove to be an expensive conversion. This specification of engine is ideal for circuit use, as it has a useable power band between 5000 and 8500 RPM, and the overall gearing of a competition car can be altered to suit this. For road use, this is not as practical a solution, although the engine will drive the car happily at speeds below the power band, the sudden increase of torque at 5000 RPM may cause a loss of traction in most gears!
Both of the two-wheel drive conversions described above can be used on an RS 500 if desired, but of course this car has the potential for far greater power outputs.
490 BHP CONVERSION - COMPLETE ENGINE REBUILD TO NEW SPECIFICATION, INCLUDING 8 INJECTOR OPERATION, GAS FLOWED CYLINDER HEAD, COMPETITION CAMSHAFTS, LOWER COMPRESSION FORGED PISTONS ETC.
We have therefore produced a conversion which is based on our Touring Car engine specification, but it is tailored towards the fast road market, and uses a standard type Weber-Marelli management system, converted to sequential 8 injector operation, and variable boost control.
The engine is totally rebuilt with a cylinder head and inlets gas flowed to Group A specification, high torque camshafts with hydraulic tappets, low compression pistons & strengthened con rod bolts. High-pressure oil pump and competition crankshaft bearings are used, with the crankshaft, flywheel, clutch, con rods & pistons being carefully balanced to full race standards. GGR high clamp cylinder head studs & nuts are used with a WRC style cylinder head gasket. The RS 500 T4 turbocharger is also fully overhauled with competition bearings and a superbalanced shaft assembly. A smaller hybrid turbocharger can also be fitted if required; to give enhanced boost response from lower engine speeds. This increase response will also result in a slight reduction in outright power as boost pressure reduces at higher RPM. The outcome of an engine converted to this specification will give excellent road driving manners, and an unbelievable level of power! The sequential operation of the 8 injectors ensures good low speed driveability from the 4 injectors fitted into the inlet manifold, and adequate fuelling at higher engine speeds and boost pressures when the extra set of injectors in the plenim cover are also used. This conversion is very popular with customers who use their road cars for occasional competitions or track days.
Please note that although it is not detailed in the above description, this type of engine conversion will also require enhancements to other engine ancillaries. The induction and exhaust systems must be changed for items with higher flow capabilities also; a higher capacity fuel pump must be fitted. In addition, the engine breather and cooling systems will require attention, please see the relevant sections of FAQs & Features and Parts List for further details.
PLEASE NOTE THAT THE CONVERSIONS DESCRIBED CAN MEET ALL CURRENT DOT EMISSIONS REQUIREMENTS.
More specific information on conversions and power increases:
Three & four door, two wheel drive cars
Four wheel drive Sierra Cosworth, (with green or red top engine)
Large turbo Escort Cosworth
Small turbo Escort Cosworth
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Correspondence/Requests
Sales Enquiries: sales@grahamgoode.com
Technical Enquiries: tech@grahamgoode.com
Tel: (+44) 0116 244 0080
Fax: (+44) 0116 244 0140

RS 500 POWER INCREASES
	The original Sierra Cosworth engine was conceived to give around 370 BHP in Group A trim, by 1987 however, more power was required. For circuit racing use, an evolution model is allowed to be homologated with certain detail improvements, and this need have a production run of only 500 models (10% of the original). The RS 500 engine specification was decided upon after consultation with the Touring Car teams who were racing Group A Cosworths. Amongst their requirements were a larger turbocharger and intake assembly, the facility to use two injectors per cylinder, and a massive air to air intercooler. Numerous detail improvements were also included to aid reliability; a unique, strengthened cylinder block, improved oil pump and cylinder head casting were included, as were improvements to the cooling system of the engine. This created an engine that was able to produce in excess of 500 BHP in Group A trim, and a road car giving only 17 BHP more than the standard two wheel drive version. Due to the large turbocharger used, the RS 500 was not so impressive in standard form, with no appreciable turbo boost below 4500 rpm, and a noticeable increase in turbo lag, it was far more difficult to drive quickly on the road. Our own RS 500 Touring Car engines produced in excess of 540 BHP. The mechanical specification included high lift, long duration camshafts with solid tappets, cylinder head porting to our exact specifications, low compression pistons, and many of the other specialist engine components that are shown in this brochure. The turbocharger also received further attention, with a screwed thrust bearing, and a the turbine shaft assembly was the same as used by Cosworth in their Formula 1 Turbo engines. These cars also used a ZYTEK engine management system, which entailed the use of many special engine mounted sensors, a unique engine wiring loom, and special fuel injection parts. We have built a couple of road cars for overseas customers with this engine specification, but due to the high number of specialist parts required, this does prove to be an expensive conversion. This specification of engine is ideal for circuit use, as it has a useable power band between 5000 and 8500 RPM, and the overall gearing of a competition car can be altered to suit this. For road use, this is not as practical a solution, although the engine will drive the car happily at speeds below the power band, the sudden increase of torque at 5000 RPM may cause a loss of traction in most gears! Both of the two-wheel drive conversions described above can be used on an RS 500 if desired, but of course this car has the potential for far greater power outputs.

490 BHP CONVERSION - COMPLETE ENGINE REBUILD TO NEW SPECIFICATION, INCLUDING 8 INJECTOR OPERATION, GAS FLOWED CYLINDER HEAD, COMPETITION CAMSHAFTS, LOWER COMPRESSION FORGED PISTONS ETC.
	We have therefore produced a conversion which is based on our Touring Car engine specification, but it is tailored towards the fast road market, and uses a standard type Weber-Marelli management system, converted to sequential 8 injector operation, and variable boost control. The engine is totally rebuilt with a cylinder head and inlets gas flowed to Group A specification, high torque camshafts with hydraulic tappets, low compression pistons & strengthened con rod bolts. High-pressure oil pump and competition crankshaft bearings are used, with the crankshaft, flywheel, clutch, con rods & pistons being carefully balanced to full race standards. GGR high clamp cylinder head studs & nuts are used with a WRC style cylinder head gasket. The RS 500 T4 turbocharger is also fully overhauled with competition bearings and a superbalanced shaft assembly. A smaller hybrid turbocharger can also be fitted if required; to give enhanced boost response from lower engine speeds. This increase response will also result in a slight reduction in outright power as boost pressure reduces at higher RPM. The outcome of an engine converted to this specification will give excellent road driving manners, and an unbelievable level of power! The sequential operation of the 8 injectors ensures good low speed driveability from the 4 injectors fitted into the inlet manifold, and adequate fuelling at higher engine speeds and boost pressures when the extra set of injectors in the plenim cover are also used. This conversion is very popular with customers who use their road cars for occasional competitions or track days. Please note that although it is not detailed in the above description, this type of engine conversion will also require enhancements to other engine ancillaries. The induction and exhaust systems must be changed for items with higher flow capabilities also; a higher capacity fuel pump must be fitted. In addition, the engine breather and cooling systems will require attention, please see the relevant sections of FAQs & Features and Parts List for further details. PLEASE NOTE THAT THE CONVERSIONS DESCRIBED CAN MEET ALL CURRENT DOT EMISSIONS REQUIREMENTS. More specific information on conversions and power increases: Three & four door, two wheel drive cars Four wheel drive Sierra Cosworth, (with green or red top engine) Large turbo Escort Cosworth Small turbo Escort Cosworth

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Correspondence/Requests Sales Enquiries: sales@grahamgoode.com Technical Enquiries: tech@grahamgoode.com Tel: (+44) 0116 244 0080 Fax: (+44) 0116 244 0140