Revised 31/12/2011 .

Build Diary Index




When I had bought my 2 litre Sierra, I had the intention of using the original Pinto engine, albeit it would be reconditioned, but it would be the same engine.

However, the one aspect of the build which I was not confident about carrying out myself was the engine. Other parts I could deal with, I just wanted to know that all I had to do was connect up the wiring, fuel and cooling system and the thing would start.

The more I looked at web sites from the likes of Vulcan and Specialised, the more I decided that there was only one choice - it had to be the full 2.1litre 160bhp option. I requested quotes for the following specification :

2.1 Ltr 160 bhp road version engine
Twin 45 DCOE Webers
Standard clutch
Alternator, brackets and fan belt
Non vacuum distributor, leads and plugs
Water pump
Petrol pump
breather system
 K & N air filters
Lumentation electronic ignition pack
Lead free conversion
Shallow sump
Alloy rocker cover

Vulcan quoted 2993.25 including VAT and an 80 discount for being a Dax owner

Specialised quoted 2797.08 including VAT and a 10% discount for being a Dax owner, however price did not include for an alloy rocker cover.

Wilcox Engines didn't quote and stated that they only build, test and develop race engines and one off development projects - they sort of implied that they don't deal with amateurs !

Burton Power failed to respond at all which surprised me.

I was just about to place an order with Vulcan when ................... I had a change of plan.

I made enquiries about a new 2.0 litre Zetec engine. In standard form with a twin 45 conversion it would achieve 165bhp, was lighter than the pinto, much more economical and more importantly could be uprated easily to 240bhp+ in the future.

Fereday Cars quoted 3848 for a brand new 2.0 Litre Zetec complete with twin 45's , 3D ECU, wiring loom, filters, raceline sump kit and water rail, alternator, etc, etc with option of 241.64 for lightened flywheel and  137.06 for fast road clutch. Alan Fereday also provided pictures of what looks like the most powerful wacker plate ever made !

Raceline failed to respond

Dunnell Engines were the only company who rang me and discussed all the issues and options available. Although they offered the most expensive solution, I was confident that I would get what I set out to achieve, a fully working engine that could just be installed, connected and started - I'm sure it's not that simple!

If I chose the option of twin throttle bodies, with Dunnell's 'Clubman's Fuel Injection and ignition Management System', 175bhp would be achieved. The engine would be dynamometer tested prior to leaving the workshop which would mean no further tuning or adjusting once I got it home.

For just over 5000 including VAT (about 2000 over my original budget), Dunnell would supply the following.

2.0 litre Zetec Engine from Ford Motorsport  

Picture does not show throttle body arrangement

Clubman's fuel injection & ignition management system (click to see data sheet), including throttle bodies, injectors, manifold and 3D programmable ECU c/w software RMP1590
Clutch cover RMP1705
Clutch Plate RMP1772
Alternator kit (click to see data sheet) RMP1440
Lightened and balanced flywheel (click to see data sheet) RMP1305
Lightweight sump (click to see data sheet) RMP1400
Water pump RMP1430
Engine wiring loom RMP1608

My only concerns were over the SVA test with using a new engine. The injection system provides a far more economical, fuel efficient and environmentally version than that using twin carbs. Paul Dunnell would be able to supply a letter stating that the engine was constructed to a 1993 specification, allowing testing for emissions for that year. It would seem that there is a conflict over whether pre 95 engines require to be fitted with a cat. However, I was assured that the setup as specified would certainly satisfy the emissions test without a cat fitted. 

Forget about the above - finally came to my senses - going to buy a Rover V8 instead.

Came across a second hand 'as new' 3.5 Rover V8 and gearbox for sale on 'Find-it' web site. The engine was to be fitted into a Magnum Cobra replica being built for a customer by Smax at Fastco-UK Ltd, but considered too small. When you see the car that Smax drives, any Rush owner, no matter what engine was fitted would admit defeat in a race - it would be past 200mph in the time a rush would get to 60 !


click on thumbnails to enlarge