Welcoem to posts!!
in the future - u will be able to do some more stuff here,,,!! like pat catgirl- i mean um yeah... for now u can only see others's posts :c
THE BROTHERS LLOYD.................www.lloydracing.com....................THE BROTHER
Hi, thanks for the interest in our cars and our racing. I say "our cars" as myself and my brother both have cosworth race cars. I
will ramble a little if that's OK. We have been racing for about ten years and in that time Gareth has raced formula first, escort
rs turbo's, polo G40's, and his monstrous escort Cosworth. I started with an XR4i, then sapphire cosworth, Grp "A" RS500,
Holden Commodore, Honda Civic and BTCC Cavalier.
Between us we have been "Modified Cosworth Champions" in 1994,95,96,97,
"Ford Saloon Car Champions" in 1996,97 and
"Formula Saloons Champion" in 1999. I was 6th privateer at Bathurst in the Commodore in 1998, 5th in class in the
Nurburgring 24hr in 1999 in the civic, and 6th at Bathurst in 1999 in the ex-Cleland BTCC Cavalier.
We are now embarking on a new challenge, this is based around an M.S.D.built Vauxhall Vectra to race in the Nurburgring
endurance races including the 24hr.
Andy Lloyd.
My RS5OO is the first Dick Johnson Sierra (it is stamped on the shell,DJR 1) and raced in the Australian Touring Cars in 1987
+ 1988. It came to England in late '88 to compete in the Silverstone Tourist Trophy Race, which it was leading until it had a
small mechanical fault and was retired, it was proved that the car was quicker than the Rouse, and Eggenberger cars ! In 1989
it was raced by Robb Gravett in Trakstar colours in the BTCC, and in 1990 was raced by Graham Hathaway in the BTCC and
in Malaysia.
It has a Grp"A" 1989 spec engine on 8 grey's with a Bosch management system with integral MAP sensor. A large
capacity baffled sump and twin oil coolers. T-4E turbo ( serviced by Vince, at Turboshop ) taking cool air from a forward facing
Carbon fibre air box. Grp "A" intercooler and alloy radiator. These days the exhaust system is full length with two silencers( to
try and keep the noise to a level that allows me on the tracks). Fuel is from a bag tank, via 1 low pressure, and 2 high pressure
pumps. An AP multi-plate clutch transmits power to a "Getrag" 5 speed gearbox with integral oil pump and underfloor cooler.
A two-piece propshaft connects to an Australian "Harrop" "spool diff"
, this is a diff unit without an actual differential, just a
crownwheel and pinion. This is kept cool by a pump and rear mounted cooler.
The suspension is by Bilstein and the damping is non-adjustable, but the front and rear anti-roll bars are. The rear suspension
arms are cast alloy and fully adjustable. Braking is AP at the front, and Alcon at the rear with Carbon Metallic pads. The front
calipers are wide endurance spec that take brake pads that are 30mm thick, and disc's of 32mm thickness by 330mm dia.
Wheels are BBS 3 piece in 16" or 17" that take 245 width tyres all round. Inside there is a race seat and harnesses, plumbed
in fire extinguisher system, and gauges for boost,oil pressure,oil temp,water temp,revs,battery charging,gearbox oil temp,diff
oil temp,fuel pressure and exhaust gas temp. There are switch's for ignition,fuel pump's,diff pump,radiator cooling fan,rear fog
light, and brake cooling pump. Brake bias is adjustable from the dash. Air jacks are fitted, and are charged by a quick-release
fitting at the front of the car.
When I raced the car, and won the "Ford Modified Saloon Car Championship" in 1997, the boost was set to 28psi, this was
ideal because if you run the maximum boost ( 34psi ) the car would spin the control yokohama's in fifth !
Gareth's Escort Cosworth was first raced by him in 1994, in the "Ford Saloon Car Championship"
, it has his own spec 8-
injector engine with data-logging and anti-lag. T-4E turbo, again by Vince at Turboshop, with air injector control. The clutch is
AP multi-plate, and the gearbox is a "7-speed" 4 wheel drive, works unit with integral oil pump. Brakes are AP all round with
water cooling at the front. Suspension is by double adjustable "LEDA" units.
This car's acceleration is "awesome". Gareth won the "Ford Saloon Car Championship" in 1996, and the "Formula Saloons
Championship" in 1999 in this car.
As you can see from the info above, Gareth gives little away about his car !
In the words of Andy Lloyd.
Gareth Lloyd
ESCORT COSWORTH BODY
SHELL WITH FULL WELDED IN
ROLL CAGE
OUR OWN BUILD RS500 BASED
ENGINE WITH EXCESS OF
550bhp, USING A T4-E AND ANTI LAG, AIR INJECTORS,
DISTRIBUTORLESS IGNITION,
ONE OFF BAYJOO MAPPING
PECTEL ON BOARD DATA
LOGGING SYSTEM
MULTI-PLATE AP CLUTCH
SEVEN SPEED WORKS
GEARBOX WITH BIG DIFFS AND
MAGNESIUM SUMP
FULLY ADJUSTABLE
SUSPENSION GEOMETRY WITH
LEDA DAMPERS ALL ROUND
WATER COOLED 355mm FRONT
DISC'S AND AP CALIPERS
18" RACELINE WHEELS
Andy Lloyd
EX-DICK JOHNSON RS500 ATCC
WINNING CAR OF 1987,88
FULL WELDED IN CAGE
1987 SPEC RS500 ENGINE WITH
530bhp, USING A T4-E
MULTI-PLATE AP CLUTCH
GETRAG 5-SPEED GEARBOX
WITH COOLER
HARROP 9" SPOOL DIFF ( no
actual diff, just a c/w and pinion )
ALUMINUM REAR ARMS
FULLY ADJUSTABLE
SUSPENSION GEOMETRY WITH
BILSTEIN DAMPERS ALL ROUND
WATER COOLED 330mm FRONT
DISC'S WITH ENDURANCE SPEC
AP CALIPERS
16" AND 17" BBS SPLIT RIM
WHEEls
THE BROTHERS LLOYD.................www.lloydracing.com....................THE BROTHER
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Escort Cosworth
The Ford Escort Cosworth was based on the two door, front wheel drive MK5 Escort shell.
The Engine
The Cosworth YBT engine was based on the 4dr Sierra 4WD Cosworth unit.
Bore 90.8 mm stroke 77mm Compression ratio 8:1
Weber-Marelli electroinc fuel and engine management system
Garrett T3/T04 turbocharger factory set at 0.8 bar boost pressure.
Max power 227bhp at 6250 rpm with max torque 220 lb.ft at 3500 rpm.
The engine was mounted longitudinally in the Mark V shell, compared to the MK5 RS2000 which was mounted transversely.
The engine ran on Unleaded Fuel and used a catalytic converter on the exhaust system. This restricted the exhaust system flow considerably. The engines were green to indicate an Unleaded fuel version. After August 1994 various engine revisions were made which included a smaller turbocharger and revised ECU mappings. This was to increase the driveability of the car but reduces tuneability of the engine. The large turbo versions can blow and retain higher boost levels further up the rev range, but with standard boost the engine can suffer from turbo lag.
The 2 door shell needed extensive modifications to use the larger Cosworth engine and transmission
Transmission
Permanent four wheel drive with 34/66% front/rear power split 5 Speed MT-75 manual five speed gearbox.
uspension and Steering
Independent front and rear Fichtel and Sachs gas telescopic dampers with 28 mm front anti-roll bar and 22mm rear. Power assisted rack and pinion steering with 2.45 runs lock to lock. Both front and rear brake disks were employed the front brakes using single pot items of a similar design to those fitted to the MK4 Escort Series 2 Turbo.
Body Work and Interior
The rear tail gate featured a large double whale tail spoiler, bringing back memories of the Sierra 3 door Cosworth. The Escort was later available with a smaller rear spoiler which was necessary for type approval in countries such as Switzerland.
Front Recaro bucket seats, with adjustable head restraints were used. Leather being an optional extra. Later a limited edition was available named The Monte Carlo.
Tilt and Slide FFSR (Factory Fitted Sun Roof), Electric windows and mirrors, Central Locking, and Tinted Glass, were all standard equipment.
The Escort Cosworth was produced until 1995, when another affordable super car went the way of the dinosaurs!
UK price guide (Sterling)
Condition Excellent Good Average
Sterling 23000 17000 15000
As with the RS Turbo prices have increased in 1997 and 1998.
Note: The FORD Escort Cosworth was produced on J to N-registration plates in the UK, with late registered vehicles on P and R-registrations.
For further details see Vehicle Registration Plate Guide.
NOTE: For turbo longevity it is recommended that the Escort Cosworth along with all other turbocharged RS models run with fully synthetic oil. These types of oil give the necessary engine protection for the high temperatures attained in turbocharged vehicles. The following viscosity synthetic oils are recommended: 5w50, 10w40, 15w50, 10w60.
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4dr Sierra RS Cosworth 4wd
The vehicle shell was based on the Sierra 4dr shell with boot.
The vehicle was available from 1990 in both RHD (Right Hand Drive) for the UK market, and LHD (Left Hand Drive) for Europe.
The Engine
As per the Sierra 4dr 2WD Cosworth with the following differences:
A Cosworth revised head and stronger cylinder block to prevent head gasket failure which affected the earlier Sierra 3 door Cosworth, and Sierra 4dr 2WD Cosworth.
The revised head featured an improved combustion chamber design and was sturdier around the exhaust valves, where head gasket failure was likely to occur.
An improved cast iron exhaust manifold was used to reduce vibration and the chance of stress induced cracks.
This 4WD Cosworth model's intercooler was enlarged by 25% to further aid cooling. Higher engine output power had to be achieved to overcome the restriction of the catalytic converter.
Although engine power output was improved over the 2WD model, any speed gain was lost due to front wheel transmission loses. Output power was claimed as 224 bhp at 6000 rpm.
The engine was converted to run on Unleaded Fuel and this Unleaded unit used a catalytic converter on the exhaust system. This restricted the exhaust system flow considerably. Fuel injection used Weber/Marelli equipment.
All Cosworth engines are fitted with hardened valve seat inserts and can therefore run continuously on unleaded fuel. With ordinary unleaded petrol it is necessary to retard the ignition by 4 Degrees. A power loss of approximately 10 bhp will be experienced after the ignition is retarded. Retarding the ignition may not be necessary if the engine is always run on Super unleaded fuel.
Red coloured engines indicate a 4 Star petrol unit and green an Unleaded Petrol only version.
Gearbox and Transmission
The main area of modification over the 2WD model was obviously due to powering the front wheels. Hence the transmission was a complete new design with drive rods to the front two wheels. A mechanical Anti-Lock Braking
System (ABS) was also employed on this new 4WD model.
Body Work and Interior
As per the Sierra 4dr 2WD Cosworth with the following differences:
Different style bonnet vents.
New style alloy wheels with locking hub caps.
Driving lamps mounted within the front spoiler.
Available colours where:
White
Graphite Grey
Metallic Magenta
Smokestone Blue
Optional extras where:
Black leather interior
Air Conditioning
On board fuel computer
Electric tilt and slide sun roof.
The Sierra 4dr 4WD was produced until 1993, when sadly the 4dr was discontinued to make way for Fords new rep-mobile the Mondeo (yawn, yawn!). Although Ford's alliance with Cosworth continued in the form of the MK5 Escort
RS Cosworth.
UK price guide (Sterling)
Condition Excellent Good Average
Sterling 12000 9000 8000
Note: The FORD Sierra 4dr Cosworth 4WD was produced on G to K-registration plates in the UK.
For further details see Vehicle Registration Plate Guide.
NOTE: For turbo longevity it is recommended that the Sierra Cosworth along with all other turbocharged RS models run with fully synthetic oil. These types of oil give the necessary engine protection for the high temperatures attained in turbocharged vehicles. The following viscosity synthetic oils are recommended: 5w50, 10w40, 15w50, 10w60.
The Sierra 4dr Cosworth was based on the 2wd Sierra 4dr of the time. Further details of which can be found in the Ford Sierra 1982 Workshop manual.
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4dr Sierra RS Cosworth Rwd
The vehicle was available in both RHD (Right Hand Drive) for the UK market, and LHD (Left Hand Drive) for Europe.
The Engine
The engine was based on the " Sierra 3 door Cosworth unit.
The Cosworth engine was coloured red to indicate it could be run on Four Star leaded petrol. Fuel injection used Weber/Marelli equipment.
All Cosworth engines are fitted with hardened valve seat inserts and can therefore run continuously on unleaded fuel. With ordinary unleaded petrol it is necessary to retard the ignition by 4 Degrees. A power loss of approximately 10 bhp will be experienced after the ignition is retarded. Retarding the ignition may not be necessary if the engine is always run on Super unleaded fuel.
Brakes
Front brakes where four pot items on vented disks. Rear braking was also via disks.
Body Work and Interior
Some complaints were heard on the release of this new shape 4dr Cosworth that the dashboard was particularly bland. For such a high performance engine only minimal instrumentation was fitted.
Front Recaro bucket seats, with adjustable head restraints were used.
Tilt and Slide FFSR (Factory Fitted Sun Roof), Electric windows and mirrors, Central Locking, and Tinted Glass, were all standard equipment.
Available colours where:
White
Graphite Grey
Black (only 12 built)
The Sierra 4dr Cosworth had colour coded front spoiler, side skirts and rear boot mounted spoiler.
The 4dr Sierra 2WD was produced until 1990, when the new 4 wheel drive 4dr Sierra 4WD Cosworth replaced it.
UK price guide (Sterling)
Condition Excellent Good Average
Sterling 9500 8500 7000
Note: The FORD Sierra Cosworth 4dr 2WD was produced on E to H-registration plates in the UK.
For further details see Vehicle Registration Plate Guide.
NOTE: For turbo longevity it is recommended that the Sierra Cosworth along with all other turbocharged RS models run with fully synthetic oil. These types of oil give the necessary engine protection for the high temperatures attained in turbocharged vehicles. The following viscosity synthetic oils are recommended: 5w50, 10w40, 15w50, 10w60.
The 4dr Sierra Cosworth was based on the Sierra Sapphire of the time. Further details of which can be found in the Ford Sierra 1982 Workshop manual.
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The Sierra Cosworth 3 door
The vehicle shell was based on the bottom of the range 3 door Sierra shell retaining the basic two rear side windows and two front doors. The dashboard was taken from the American Sierra XR4Ti which included the turbo boost gauge. Design knowledge was similarly taken from the American Sierra XR4Ti Merkur. The car was designed by Ford's Special Vehicle Engineering (SVE) group and manufactured at Ford's Genk, Belgium operation. The Sierra HYPERLINK "www.cosworth.co.uk/" Cosworth was launched in July 1986 and 5545 were manufactured in total of which 500 were sent to Tickford for conversion to the HYPERLINK "www.turbocharger.co.uk/rs-cosworth-rs500.html" Sierra 3 door RS500 Cosworth. The vehicle was manufactured in both RHD (Right Hand Drive) for the UK market, and LHD (Left Hand Drive) for Europe. The following number of vehilces were registered in the UK:
1985 10
1986 1064
1987 579
Total: 1653
Many of these cars were used very successfully for racing, in both rally and road events:
The Engine
Development of the HYPERLINK "www.cosworth.co.uk/" Cosworth engine was started way back in 1982 on a non-turbo, 16-valve, Dual Over Head Cam (DOHC) version. This version was coded YAA. Ford planned to use this engine, but TURBOcharged it!
This turbo version became the first Ford Cosworth engine and was coded YBB (nothing like a logical naming convention). The first production began in 1987 after further development of the engine by Cosworth. The first engines to be used by Cosworth in the two wheel rear drive (3 door) Sierra was coded YBD and had a measured output of 204 bhp at 6000 rpm. Peak torque was 203 lbs ft at 4000 rpm. No diesels here!
The engine specifications were:
Displacement:
1993 cc
Bore:
90.8 mm
Stroke:
77 mm
Compression Ratio:
8.0:1 with pentroof combustion chambers
Inlet Valves
35mm operated via bucket tappets
Exhaust Valves
31mm (sodium cooled) operated via bucket tappets
Cam shafts
Running five bearings
Turbocharger: HYPERLINK "www.alliedsignal.com/business/turbo/index.html" Garrett AirResearch TO3 unit with integral waste gate and water cooled centre-housing. As originally fitted to the HYPERLINK "www.turbocharger.co.uk/rs-turbo-series1.html" MK3 Escort Series 1 Turbo.
Turbo HYPERLINK "www.turbocharger.co.uk/pressure.html" boost pressure:
9 psi
Injection and Ignition system:
Weber-Marelli multi-point fuel injection
Oil Cooler
Water to oil intercooler mounted on the side of the block
Both crankshaft and conrods were heat-treated steel items to add further strength to the engine.
The turbocharger also used a dump valve which let the turbo keep spinning when the throttle was released. Thus improving the engines response times. The TO3 turbo was mounted on top of the high nickel content exhaust manifold. A special mounting plate was used to allow the turbo to grow as it got hotter without cracking or causing undue stress.
The compressed air exiting the turbo was feed to an air-to-air intercooler mounted next to the engine coolant radiator.
Cosworth chose belt drive for the twin overhead cam engine. These Uniroyal rubber reinforced fibreglass items were used to power the oil pump and distributor.
The engine also used a high pressure oil pump needed to feed the spray jets, which pointed underneath the Mahle forged piston crowns.
(The engine and turbo system had great tuning potential as detailed in the HYPERLINK "www.turbocharger.co.uk/rs-turbo-series2.html" MK4 Escort Series 2 Turbo page.)
The engine was coloured red to indicate it could be run on Four Star leaded petrol.
All Cosworth engines are fitted with hardened valve seat inserts and can therefore run continuously on unleaded fuel. With ordinary unleaded petrol it is necessary to retard the ignition by 4 Degrees. A power loss of approximately 10 bhp will be experienced after the ignition is retarded. Retarding the ignition may not be necessary if the engine is always run on Super unleaded fuel.
This took the Ford Sierra from being a boring rep-mobile into a fire breathing road rocket. This set Cosworth and Ford on a ten year path together producing one of the best affordable super cars.
Variations of this successful engine were subsequently used in the:
HYPERLINK "www.turbocharger.co.uk/rs-cosworth-rs500.html" Sierra 3 door RS500 Cosworth
HYPERLINK "www.turbocharger.co.uk/rs-cosworth-2wd.html" Sierra Sapphire 2WD Cosworth
HYPERLINK "www.turbocharger.co.uk/rs-cosworth-4wd.html" Sierra Sapphire 4WD Cosworth
HYPERLINK "www.turbocharger.co.uk/rs-cosworth-escort.html" MK5 Escort RS Cosworth
The Management Engine System
This Cosworth engine, like its turbocharged stable mate the HYPERLINK "www.turbocharger.co.uk/rs-turbo-series1.html" MK3 Escort Series 1 Turbo, used a sophisticated engine management system. This system controlled:
Ignition timing
Fuel injection used Weber/Marelli equipment
Fuel pressure
Turbo HYPERLINK "www.turbocharger.co.uk/pressure.html" boost pressure
Gearbox and Transmission
The Sierra Cosworth used a five speed manual gearbox mounted at the rear of the engine. This fed the prop shaft which then fed power via the rear differential to the back wheels. The gearbox was a Borg-Warner T5 5-speed unit taken from the 2.3 Turbo Mustang with a modified 5 gear ratio. The rear differential was a Ferguson-type 7.5 inch viscous unit.
The 11.1 inch brake front disks were 0.94 inches thick and used Ferodo F3432 pads. The front calipers were high performance four pot items.
Suspension and Chassis
Steering was non power-assisted and used a rack and pinion. Front suspension was via independent MacPherson struts with anti-roll bar. Dampers were gas filled twin tube units from Fichtel and Sachs, the preferred supplier to the Ford SVE group for all Ford Cosworths.
The rear suspension used much of the Sierra XR4 4WD layout. It used trailing rear arms with uniball joints and again Fichtel and Sachs gas filled damper units.
Body Work and Interior
With the Sierra's huge whale tail this car could not be described as a street sleeper by any stretch of the imagination. Much design had gone into this rear fin to produce a large down force. The down force was measured at 164 Nm (124 mph wind tunnel test) compared with the standard 3 door Sierra's of 513 Nm UPLIFT!
Available colours where:
Black
White
Moonstone Blue
BBS style Rial manufactured alloy wheels sported the new HYPERLINK "www.dunloptire.com/" Dunlop D40 205/50 x 15 VR low profile tyres.
This Sierra Cosworth featured colour coded bumpers, side skirts and mirrors. Driving lamps mounted within the front spoiler came as standard.
In 1987 a limited edition uprated version of this Sierra Cosworth was produced, it was named the HYPERLINK "www.turbocharger.co.uk/rs-cosworth-rs500.html" RS500 since only 500 were produced.
The Sierra Cosworth 3 door was produced from 1986 to 1988, when the HYPERLINK "www.turbocharger.co.uk/rs-cosworth-2wd.html" Sierra 4 door 2WD Cosworth based on the new design Sierra 4 door shell replaced it.
UK price guide (Sterling)
Condition Excellent Good Average
Sterling 10000 9000 7500
Note: The FORD Sierra Cosworth 3-door was produced on C to E-registration plates in the UK.
For further details see HYPERLINK "www.turbocharger.co.uk/rs-registrations.html" Vehicle Registration Plate Guide.
NOTE: For turbo longevity it is recommended that the Sierra Cosworth along with all other turbocharged RS models run with fully synthetic oil. These types of oil give the necessary engine protection for the high temperatures attained in turbocharged vehicles. The following viscosity synthetic oils are recommended: 5w50, 10w40, 15w50, 10w60.
The Sierra Cosworth was based on the Sierra of the time. Further details of which can be found in the Ford Sierra 1982 Workshop manual.
5 - 0
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2002 Cosworth Chronicles
All Copyrights Acknowledged
1 - 0
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