Large Turbo Escort Conversion

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LARGE TURBO ESCORT COSWORTH POWER CONVERSION
The original large turbo Escort is another Cosworth that was designed for motorsport applications, and because of this, it has excellent tuning potential. By the time this model was introduced, homologation requirements had changed. Group A rallying required a production run of only 2500 cars, and there was no provision for an evolution model.
In 1992, Cosworth enthusiasts made every possible effort to purchase what they thought would be the car of their dreams. Full time four wheel drive, anti-lock braking, innovative positive downforce aerodynamics, and a turbocharger sized mid-way between the ordinary Cosworth, and the legendary RS 500 unit, on paper the specification looked ideal.
Unfortunately, the on the road performance usually didn't meet their expectations, especially as most people had traded up to the Escort from a modified Sierra Cosworth.
We received our Escort Cosworth (K 64 CAR) in August 1992, and set to work rectifying this situation. By the end of October, we had a range of conversions and parts available for the car.

325/335 BHP CONVERSION - HIGH FLOW FUEL PUMP, MATCHED SET OF HIGHER FLOW RATE FUEL INJECTORS, ADDITIONAL BABYBOARD & EPROM, EXHAUST SYSTEM MODIFICATIONS.
The power output of the standard car is governed by a number of factors. The small bore and catalysed exhaust system, the flow rates of the fuel injectors and the fuel pump, plus the calibration of the management system, to name a few.
The highest level of power that can be safely attained from a standard specification engine is 335 BHP, and we have achieved this without compromising any of the standard cars attributes. In fact, we have managed to improve almost every aspect of the engine efficiency, including fuel consumption!
The basic principles of Cosworth engine tuning are the same with this model, but we have found that a lower level power increase (around 275 BHP) was not required. With the traction & stability that the Escort Cosworth has, higher power outputs are not a problem. To raise the power of this model, we fit a set of higher flow fuel injectors, a larger capacity fuel pump, a new circuit board (babyboard) & chip (eprom) to the management system, and modify the exhaust system to reduce restrictions. The exhaust system modifications consist of either a complete replacement 3" bore system, (with or without non-restrictive sports catalyst), or the removal & replacement of the first catalysed section. With the smaller bore exhaust system, the maximum power raises to 325 BHP, but with the complete 3" system this becomes 335 BHP, with an additional increase in torque all through the rev range. With the retention of closed loop control of the fuelling, and using either our sports catalyst equipped system, or the standard secondary catalytic converters, cars fitted with this conversion will pass all current DOT exhaust emissions test regulations.
FAST LANE MAGAZINE tested the GGR demonstrator car in December 1992, and provided the following performance figures. (The figures in brackets are for a standard car tested on the same day).
STANDING START ACCELERATION
0 to 30 in 1.4 seconds (1.9 seconds)
0 to 60 in 4.3 seconds (5.7 seconds)
0 to 100 in 12.8 seconds (16.6 seconds)
0 to 120 in 19.1 seconds (26.8 seconds)
FOURTH GEAR ACCELERATION
30 to 50 in 8.1 seconds (9.7 seconds)
50 to 70 in 4.3 seconds (5.5 seconds)
70 to 90 in 3.8 seconds (5.9 seconds)
TOP GEAR ACCELERATION
50 to 70 in 7.2 seconds (9.6 seconds)
70 to 90 in 5.1 seconds (8.2 seconds)
90 to 110 in 6.8 seconds (11.2 seconds)
Please note that further improvements to power & response can be made by fitting the GGR cone & trumpet induction kit to cars fitted with this conversion.

375 BHP CONVERSION -AS ABOVE PLUS: GAS FLOWED CYLINDER HEAD, WRC TYPE HEAD GASKET, HIGH CLAMP STUD & NUT KIT, MATCHED SET OF HIGHER FLOW FUEL INJECTORS, NEW EPROM, 3 BAR MAP SENSOR.
Within a short time, many customers with 335 BHP cars were asking for an additional conversion with even more power. We set out to develop a conversion that would increase the power available, without detracting in any way from the original objective, (to produce a quick, reliable & enjoyable road car that could be used in every situation).
Engine performance was improved even further without sacrificing the exceptional low speed driveability of the original conversion. The cylinder head and inlet tracts are gas flowed to Group A specification, and to add to the mechanical reliability, a WRC type head gasket is used in conjunction with GGR's own cylinder head stud & nut kit. The improved breathing characteristics created by the gas flowed cylinder head, and the higher boost pressures used in this conversion have also necessitated in a change of injector size, and the use of a 3 bar MAP sensor. Suitable modifications to the mapping of the engine management system to match these changes have given an engine with a power band that extends to the new 7000 RPM rev limit (originally, engine torque reduced significantly above 5500 RPM), without any reduction in low speed driveability.
This conversion is usually carried out on cars that were previously converted to 335 BHP specification. The fuel pump, management system babyboard and 3" bore exhaust system are all reused within this conversion. With our sports catalyst equipped exhaust system fitted, this conversion will also pass all current DOT exhaust emission test regulations. To benefit from the effects of this conversion, the standard air filter should be replaced with our cone & trumpet air filter assembly. It is also strongly recommended that an engine breather system be fitted.
Please note that we have now updated K 64 CAR to this specification, and test drives can be arranged if required.
More specific information on conversions and power increases:
Three & four door, two wheel drive cars
RS 500
Four wheel drive Sierra Cosworth, (with green or red top engine)
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

LARGE TURBO ESCORT COSWORTH POWER CONVERSION
	The original large turbo Escort is another Cosworth that was designed for motorsport applications, and because of this, it has excellent tuning potential. By the time this model was introduced, homologation requirements had changed. Group A rallying required a production run of only 2500 cars, and there was no provision for an evolution model. In 1992, Cosworth enthusiasts made every possible effort to purchase what they thought would be the car of their dreams. Full time four wheel drive, anti-lock braking, innovative positive downforce aerodynamics, and a turbocharger sized mid-way between the ordinary Cosworth, and the legendary RS 500 unit, on paper the specification looked ideal. Unfortunately, the on the road performance usually didn't meet their expectations, especially as most people had traded up to the Escort from a modified Sierra Cosworth. We received our Escort Cosworth (K 64 CAR) in August 1992, and set to work rectifying this situation. By the end of October, we had a range of conversions and parts available for the car.

325/335 BHP CONVERSION - HIGH FLOW FUEL PUMP, MATCHED SET OF HIGHER FLOW RATE FUEL INJECTORS, ADDITIONAL BABYBOARD & EPROM, EXHAUST SYSTEM MODIFICATIONS.
	The power output of the standard car is governed by a number of factors. The small bore and catalysed exhaust system, the flow rates of the fuel injectors and the fuel pump, plus the calibration of the management system, to name a few. The highest level of power that can be safely attained from a standard specification engine is 335 BHP, and we have achieved this without compromising any of the standard cars attributes. In fact, we have managed to improve almost every aspect of the engine efficiency, including fuel consumption! The basic principles of Cosworth engine tuning are the same with this model, but we have found that a lower level power increase (around 275 BHP) was not required. With the traction & stability that the Escort Cosworth has, higher power outputs are not a problem. To raise the power of this model, we fit a set of higher flow fuel injectors, a larger capacity fuel pump, a new circuit board (babyboard) & chip (eprom) to the management system, and modify the exhaust system to reduce restrictions. The exhaust system modifications consist of either a complete replacement 3" bore system, (with or without non-restrictive sports catalyst), or the removal & replacement of the first catalysed section. With the smaller bore exhaust system, the maximum power raises to 325 BHP, but with the complete 3" system this becomes 335 BHP, with an additional increase in torque all through the rev range. With the retention of closed loop control of the fuelling, and using either our sports catalyst equipped system, or the standard secondary catalytic converters, cars fitted with this conversion will pass all current DOT exhaust emissions test regulations. FAST LANE MAGAZINE tested the GGR demonstrator car in December 1992, and provided the following performance figures. (The figures in brackets are for a standard car tested on the same day). STANDING START ACCELERATION 0 to 30 in 1.4 seconds (1.9 seconds) 0 to 60 in 4.3 seconds (5.7 seconds) 0 to 100 in 12.8 seconds (16.6 seconds) 0 to 120 in 19.1 seconds (26.8 seconds) FOURTH GEAR ACCELERATION 30 to 50 in 8.1 seconds (9.7 seconds) 50 to 70 in 4.3 seconds (5.5 seconds) 70 to 90 in 3.8 seconds (5.9 seconds) TOP GEAR ACCELERATION 50 to 70 in 7.2 seconds (9.6 seconds) 70 to 90 in 5.1 seconds (8.2 seconds) 90 to 110 in 6.8 seconds (11.2 seconds) Please note that further improvements to power & response can be made by fitting the GGR cone & trumpet induction kit to cars fitted with this conversion.

375 BHP CONVERSION -AS ABOVE PLUS: GAS FLOWED CYLINDER HEAD, WRC TYPE HEAD GASKET, HIGH CLAMP STUD & NUT KIT, MATCHED SET OF HIGHER FLOW FUEL INJECTORS, NEW EPROM, 3 BAR MAP SENSOR.
	Within a short time, many customers with 335 BHP cars were asking for an additional conversion with even more power. We set out to develop a conversion that would increase the power available, without detracting in any way from the original objective, (to produce a quick, reliable & enjoyable road car that could be used in every situation). Engine performance was improved even further without sacrificing the exceptional low speed driveability of the original conversion. The cylinder head and inlet tracts are gas flowed to Group A specification, and to add to the mechanical reliability, a WRC type head gasket is used in conjunction with GGR's own cylinder head stud & nut kit. The improved breathing characteristics created by the gas flowed cylinder head, and the higher boost pressures used in this conversion have also necessitated in a change of injector size, and the use of a 3 bar MAP sensor. Suitable modifications to the mapping of the engine management system to match these changes have given an engine with a power band that extends to the new 7000 RPM rev limit (originally, engine torque reduced significantly above 5500 RPM), without any reduction in low speed driveability. This conversion is usually carried out on cars that were previously converted to 335 BHP specification. The fuel pump, management system babyboard and 3" bore exhaust system are all reused within this conversion. With our sports catalyst equipped exhaust system fitted, this conversion will also pass all current DOT exhaust emission test regulations. To benefit from the effects of this conversion, the standard air filter should be replaced with our cone & trumpet air filter assembly. It is also strongly recommended that an engine breather system be fitted. Please note that we have now updated K 64 CAR to this specification, and test drives can be arranged if required. More specific information on conversions and power increases: Three & four door, two wheel drive cars RS 500 Four wheel drive Sierra Cosworth, (with green or red top engine) Small turbo Escort Cosworth

Back to Power Conversions · Back to FAQs & Features · GGR Home
Correspondence/Requests Sales Enquiries: sales@grahamgoode.com Technical Enquiries: tech@grahamgoode.com Tel: (+44) 0116 244 0080 Fax: (+44) 0116 244 0140