4wd Sierra Conversion

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FOUR WHEEL DRIVE SIERRA COSWORTH POWER CONVERSION
The 4x4 Sapphire Cosworth was introduced to the World early in 1990. A catalogue of small improvements made to the engine for this new model, incorporating a number of the improvements designed originally for the RS 500. A new strong cylinder block (known as the 200 block) was made, very similar to the rare RS 500 unit, but full production specification. The other major alteration of design was to the exhaust manifold & turbocharger. This was a more compact and rigid design, reducing turbo lag, and a resonation that was a feature of the earlier cars. This alteration to the exhaust limits the potential maximum power output of the 4x4 engine to about 430BHP. The cylinder head was also redesigned, with the combustion chambers now a true hemispherical shape, and further improvements made to coolant passages. The 4x4 engine was produced in two basic versions, with either red or green camshaft covers. A red top engine was designed to run on leaded fuel, without a catalysed exhaust system. Green top engined cars were fitted with catalysed exhaust systems; a Lambda sensor to measure exhaust emissions, and should run on un leaded fuel. These are the only major differences between these two engines. The maximum power output of the both engines was 227BHP, an increase over the original two wheel drive engines due to improvements in design and combustion efficiency.

280 BHP CONVERSION- REPLACEMENT EPROM (AND DE-CATALYSED EXHAUST DOWNPIPE FOR GREEN TOP ENGINES)
As with the two wheel drive car, the limiting factor with power & reliability is the quantity of fuel that can be supplied by the original size injectors. In principle, this conversion is very similar to the level one, two wheel drive conversion. Thanks to our access to the added sophistication's of the later type of engine management system used on the 4 wheel drive cars, and the quality of the original component, we are not required to change the wastegate actuator for this conversion. For cars fitted with green top engines & catalysed exhaust systems we find it necessary to remove the first catalyst which is fitted to the exhaust system directly after the turbocharger. If this isn't removed, it may overheat and disintegrate, blocking the remaining exhaust system, and cause a lack of power due to increased exhaust back pressure. The retention of the centre catalysts and closed loop lambda control of the engine management system will ensure that the car will still pass all current DOT exhaust emission test regulations. This conversion will give a noticeable increase in performance to the car, without any detrimental effects.

330 BHP CONVERSION - REPLACEMENT EPROM AND A MATCHED SET OF HIGH FLOW FUEL INJECTORS. (PLUS DE-CATALYSED EXHAUST DOWNPIPE FOR GREEN TOP ENGINES).
Similar to the two wheel drive Cosworth, our second level of conversion for the 4x4 cars also utilises a matched set of higher flow fuel injectors. This again allows the use of higher turbo boost pressures at higher engine speeds, and gives a significant increase in horsepower. Using larger flow injectors has necessitated in the total re mapping of the engine management system, and this has enabled us to improve even further on the low speed driveability and road manners of the car. The performance of the engine is now equal to the excellent 4 wheel drive chassis, creating a most impressive and useable road car.
As mentioned above, green top engined cars must have the first section of exhaust exchanged to remove the first catalyst. The retention of the further two catalytic converters, and our use of close loop lambda control within the engine management system will ensure compliance with all current DOT exhaust emission test regulations, despite the change to larger injectors.
Further improvements can be made with the above conversions by using our own 3" bore stainless steel exhaust systems (available with non restrictive sports catalyst if required), and cone & filter induction kits.

420 BHP CONVERSION - COMPLETE ENGINE REBUILD TO NEW SPECIFICATION, INCLUDING GAS FLOWED CYLINDER HEAD, COMPETITION CAMSHAFTS, WRC TYPE HEAD GASKET, LOWER COMPRESSION FORGED PISTONS, HYBRID TURBOCHARGER ETC.
It was explained above that changes to the exhaust manifold & turbocharger design will restrict the maximum power that the 4x4 engine can produce when compared to the 2 wheel drive version. We have created this conversion to exploit the maximum potential of this engine design. With a similar mechanical specification to the RS 500 conversion described earlier, this is also available with 8-injector operation. With an aim to reduce costs however, the original 4-injector manifold assembly can be retained, using four high flow fuel injectors. This will result in a slight decrease in low speed driveability, exhaust emissions and fuel consumption, but we feel that these are all still to acceptable levels. When this engine conversion is combined with the excellent traction of full time four wheel drive, it creates a vehicle with astonishing levels of performance & response, that is capable of carrying five full size passengers (and luggage!) in comfort.
More specific information on conversions and power increases:
Three & four door, two wheel drive cars
RS 500
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 (0)844 3911 780
Fax: (+44) 0116 244 0140

FOUR WHEEL DRIVE SIERRA COSWORTH POWER CONVERSION
	The 4x4 Sapphire Cosworth was introduced to the World early in 1990. A catalogue of small improvements made to the engine for this new model, incorporating a number of the improvements designed originally for the RS 500. A new strong cylinder block (known as the 200 block) was made, very similar to the rare RS 500 unit, but full production specification. The other major alteration of design was to the exhaust manifold & turbocharger. This was a more compact and rigid design, reducing turbo lag, and a resonation that was a feature of the earlier cars. This alteration to the exhaust limits the potential maximum power output of the 4x4 engine to about 430BHP. The cylinder head was also redesigned, with the combustion chambers now a true hemispherical shape, and further improvements made to coolant passages. The 4x4 engine was produced in two basic versions, with either red or green camshaft covers. A red top engine was designed to run on leaded fuel, without a catalysed exhaust system. Green top engined cars were fitted with catalysed exhaust systems; a Lambda sensor to measure exhaust emissions, and should run on un leaded fuel. These are the only major differences between these two engines. The maximum power output of the both engines was 227BHP, an increase over the original two wheel drive engines due to improvements in design and combustion efficiency.

280 BHP CONVERSION- REPLACEMENT EPROM (AND DE-CATALYSED EXHAUST DOWNPIPE FOR GREEN TOP ENGINES)
	As with the two wheel drive car, the limiting factor with power & reliability is the quantity of fuel that can be supplied by the original size injectors. In principle, this conversion is very similar to the level one, two wheel drive conversion. Thanks to our access to the added sophistication's of the later type of engine management system used on the 4 wheel drive cars, and the quality of the original component, we are not required to change the wastegate actuator for this conversion. For cars fitted with green top engines & catalysed exhaust systems we find it necessary to remove the first catalyst which is fitted to the exhaust system directly after the turbocharger. If this isn't removed, it may overheat and disintegrate, blocking the remaining exhaust system, and cause a lack of power due to increased exhaust back pressure. The retention of the centre catalysts and closed loop lambda control of the engine management system will ensure that the car will still pass all current DOT exhaust emission test regulations. This conversion will give a noticeable increase in performance to the car, without any detrimental effects.

330 BHP CONVERSION - REPLACEMENT EPROM AND A MATCHED SET OF HIGH FLOW FUEL INJECTORS. (PLUS DE-CATALYSED EXHAUST DOWNPIPE FOR GREEN TOP ENGINES).
	Similar to the two wheel drive Cosworth, our second level of conversion for the 4x4 cars also utilises a matched set of higher flow fuel injectors. This again allows the use of higher turbo boost pressures at higher engine speeds, and gives a significant increase in horsepower. Using larger flow injectors has necessitated in the total re mapping of the engine management system, and this has enabled us to improve even further on the low speed driveability and road manners of the car. The performance of the engine is now equal to the excellent 4 wheel drive chassis, creating a most impressive and useable road car. As mentioned above, green top engined cars must have the first section of exhaust exchanged to remove the first catalyst. The retention of the further two catalytic converters, and our use of close loop lambda control within the engine management system will ensure compliance with all current DOT exhaust emission test regulations, despite the change to larger injectors. Further improvements can be made with the above conversions by using our own 3" bore stainless steel exhaust systems (available with non restrictive sports catalyst if required), and cone & filter induction kits.

420 BHP CONVERSION - COMPLETE ENGINE REBUILD TO NEW SPECIFICATION, INCLUDING GAS FLOWED CYLINDER HEAD, COMPETITION CAMSHAFTS, WRC TYPE HEAD GASKET, LOWER COMPRESSION FORGED PISTONS, HYBRID TURBOCHARGER ETC.
	It was explained above that changes to the exhaust manifold & turbocharger design will restrict the maximum power that the 4x4 engine can produce when compared to the 2 wheel drive version. We have created this conversion to exploit the maximum potential of this engine design. With a similar mechanical specification to the RS 500 conversion described earlier, this is also available with 8-injector operation. With an aim to reduce costs however, the original 4-injector manifold assembly can be retained, using four high flow fuel injectors. This will result in a slight decrease in low speed driveability, exhaust emissions and fuel consumption, but we feel that these are all still to acceptable levels. When this engine conversion is combined with the excellent traction of full time four wheel drive, it creates a vehicle with astonishing levels of performance & response, that is capable of carrying five full size passengers (and luggage!) in comfort. More specific information on conversions and power increases: Three & four door, two wheel drive cars RS 500 Large turbo Escort Cosworth 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 (0)844 3911 780 Fax: (+44) 0116 244 0140