Im running a garage specialising in the Cosworth range of Sierras and Escorts in Norway so no surprise it was going to be a YB under the bonnet:)
Here`s the old lump, a 2 litre oil-thirsty DOHC:
And the new lump looks like this:
The T5 gearbox fitted to the Sierras would be of no use due to the position of the gearstick. I therefore decided to use a Transit MT75 box. The petrol box fitted to my old engine would probably bolt straight on, but as these are fairly rare over here I decided to use a 2,5 TD box instead, as they are to be found on any scrappie over here. I reckon the box won`t last forever in this van.
The TD box is about 6 cm shorter than the petrol box too, allowing me to mount the new engine as far back as possible. I made up an adapter plate from 8mm steel, using the heaviest YB flywheel (from the last generation Escort Cosworth) and an AP Racing 4-paddle clutch. The input splines on the MT75 is the same as on the Cosworth so this combo fits together. I used a 2wd Cossie starter, which bolted straight to the adapter plate. The TD bellhousing is big enough to fit over the whole assembly.
The rear gearbox mount is the same on the 2 Transit boxes, so fitting the engine was just a matter of hoisting the engine/box into the car and bolting it onto the rear crossmember, and then making up the main engine mounts along the way. It was made out of a mix of Pinto transit inner mounts, some 42mm steel tubing/bends and a pair of BMW E30 diff mounts
Here`s the engine fitted:
Space was far more limited than expected, which is down to the low front and sloped bonnet, compared to a Sierra front. This caused some thinking of radiator/intercooler options. I managed to fit a 2wd Cosworth rad/fans and a big intercooler I had lying around:
I drilled the front bumper to allow for maximum airflow through the coolers:
Completed the bay with a header tank from a mk5 Escort, and power steering reservoir from an Audi 80. I also incorporated an oil cooler for the PAS from a Mondeo. This fits just above the radiator.
I also had to cut away some of the bulkhead just behind the turbo, as the downpipe would be dangerously close to it. I fabricated a complete 3" exhaust system with 2 silencers, will put on a third one if its too loud.
I made up the pipes from the turbo-intercooler and intercooler -inlet from 2,5" steel tubing:
After all the new components were fitted and new mounts for ancillaries were fabricated it was all ripped out again for the engine bay to be sprayed with fresh Diamond White. With all this done it now looks like this:
It now just has a few bits missing, and the engine management system to be installed. I will be using a Link G3 management which we are importing from NZ. With the standard engine on bigger injectors we`ll see about 300-320 BHP on this lump. Upgrading the turbo to a bigger one will allow up to 380-390 BHP before head work and a bigger inlet will be needed. More than enough for this van anyway!
Adapters for a set of 8x18" Audi RS2 alloys are being made, these wheels are Porsche fitment, which means 5x130mm PCD and ET 49. Will see what mods I will have to carry out on the arches (if any) before I have the rest of the van sprayed to match the bay.
i will also fettle with the suspension to lower it, want the rear end 5 linked and modify the front struts to take adjustable insert dampers from a big BMW or similar heavy performance car
Will update on this as work continues!
Tor
Racefix Motorsport, Norway
looking a great job ,keep us posted! 
we are looking into tuning the mk6 transit cosworth we have, i am i right in thinking light greens are the ones to match a 330BHP chip 