Cosworth 2.9litre in my Crewwy

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Jim Hunter
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Re: Cosworth 2.9litre in my Crewwy

Post by Jim Hunter »

I am "prepared" for the hell as I know it wouldn't be easy :)
I will use an home made engine plate flywheel I think that I use to put a 2.8 scorpio in my van seems doable...

So I need to strip any wire from the engine bay and going backwards...Also the dash need to be removed ??? where are the brains located ? also the main one ?Also I will get the fuse panels as well?
I get the fuel pump and I will take the whole fuel tank as well to cut the section you mention.These cars here (Greece) are a rarity I was looking for one about for two years to showed up...Also did you use the power steering pump ? does it fits ?

Apologies for the lot of question :ok s

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dickspanner
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Re: Cosworth 2.9litre in my Crewwy

Post by dickspanner »

Jim,

It depends on how much you want to spend as a power steering rack is like hens teeth and you can pay rude money for one.

If it is a rare thing then I would definitely bare bone the shell and keep every part. You never know you may be able to sell the parts, here in the UK I tried selling some parts and got no interest on forums and ebay so just ended up weighing them in in the next car we stripped.

Like I said, we bare shelled the car, we took every part of the wiring harness out from the front to the rear of the car complete. The dash and everything came out and I think all the brains are located behind there.

We kept the power steering pump as I had a similar idea then just junked it when I found out how much the rack would cost. I got rid of the aircon pump so I just run the alternator with a modified spacer braket and basically just went to the local car shop and bought about 10 belts with small differences in length and then fabricated brackets to fit.

What box are you going to run the rug through and more importantly what clutch flywheel assembly, have you considered the starter.

It cost me over 3k to strip and rebuild the rig due to internal coking of the engine and getting hold of parts were very expensive so hopefully you will not have to let light into the engine.

Hopefully reading this full thread which describes each part of the build will help answer some of your upcoming questions as well.

One of the main reasons I did this in depth thread was in case someone else wanted to do a similar conversion like yourself.

Dickspanner
Crewwy now running a 2.9litre 24V V6 Injection Cosworth motor.Oh the Joy. Happy Happy Joy Joy. Mmmmmmmmm

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Jim Hunter
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Re: Cosworth 2.9litre in my Crewwy

Post by Jim Hunter »

Hello Dick,

Today I was remove the dashboard.... :shock: :shock: :shock:
I found one DME for the engine,one for the ABS (Ate) and four others !!!
Also lot of relays down there.I plan to cut the harness where it goes to the back of the car in the R/H side door sill and to remove the whole wires/fuses from the engine bay and up to where I mention above.Also where is the inertia valve ;

Rgds,
Jim

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dickspanner
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Re: Cosworth 2.9litre in my Crewwy

Post by dickspanner »

Jim,

Just follow all the wires and you will find it somewhere.

It is around 3 inches long, 2 inches high and 1 inch thick. It has 2 bolts securing it to the bodywork and a red reset button. I think mine was near the steering column but I can't remember now to be honest pal. Have you not got a haynes manual for the scorpio as that should give you an idea.

Look up a fella called madoldbugger on the internet and he publishes a schematic of what wires he kept for his conversion when he put one in his cortina I think.

We laid the entire harness out on the floor and it took about 15ft by 25ft when it was fully laid out. We then used the wiring diagrams, diagrams we got off the net from ford Australia and the madoldbugger guidelines. Traced each wire, cross checked them against the diagrams I bought and diagrams we downloaded. Double checked, treble checked then cut them. We still made mistakes and with two of us it took us three days to take it down to a sub harness that basically you earthed and put a constant positive and switched positive and it all worked first time.

The only thing I do not have is a VSS which I wired to my Tacho and due to it getting a signal of a form allowed it to work. I do have the occasional stall, which could be rectified by installing a VSS but I have never done it.

Remember the wires to the fuel pump go to the rear of the car if you are going to cut through harnesses.

We managed to get the whole harness out of the vehicle, every wire to every point without cutting a wire.

Good luck

Dickspanner
Crewwy now running a 2.9litre 24V V6 Injection Cosworth motor.Oh the Joy. Happy Happy Joy Joy. Mmmmmmmmm

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dickspanner
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Re: Cosworth 2.9litre in my Crewwy

Post by dickspanner »

Well just as an update on the crewcab and I am really glad I did not sell the crewcab at Tatton park as someone would now be thinking I tried to rip them off.

There is an oil issue on my rear cylinder on the right hand bank, I have stripped all the exhaust off and found the oil issue.

The cats are shot to pieces as well.

I am now in talks with some cosworth specialists to see if I can de-cat the system, if so then a full new exhaust will be built, I am going to my engine builder tomorrow to discuss this oil problem to see what he suggests as the engine has only done 450 miles since a very expensive rebuild.

Will keep you posted.

Dickspanner

Oh yea, picture of the system off (except one manifold)

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Crewwy now running a 2.9litre 24V V6 Injection Cosworth motor.Oh the Joy. Happy Happy Joy Joy. Mmmmmmmmm

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dickspanner
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Re: Cosworth 2.9litre in my Crewwy

Post by dickspanner »

http://s110.photobucket.com/albums/n103 ... CF6017.mp4" onclick="window.open(this.href);return false;

Video of cosworth engine running in crewcab with no exhaust on, at circa 1:30 youcan see a piece of the Cat shoot out of the exhaust.

Looks like a new exhaust needed, any suggestions?

Dickspanner
Crewwy now running a 2.9litre 24V V6 Injection Cosworth motor.Oh the Joy. Happy Happy Joy Joy. Mmmmmmmmm

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Jim Hunter
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Re: Cosworth 2.9litre in my Crewwy

Post by Jim Hunter »

Sad to hear for the engine fault in that low mileage :(
Your rebuilder does not give you any warranty for his work ???
IMHO he must be fix it.

The exhaust looks very neat :ok

I think you get the adapter from Kennedy.Is there any company that makes bellhousings with the ford patter ??? I think that maybe put the BOA in my syncro instead but it seems a lot more complicated compared to 2wd...

Rgds,
Jim

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Aidan
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Re: Cosworth 2.9litre in my Crewwy

Post by Aidan »

that sort of exhaust would be difficult in a syncro

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dickspanner
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Re: Cosworth 2.9litre in my Crewwy

Post by dickspanner »

From speaking the the Cosworth boys the cats are now dead.

The engine builder is hopefully coming up on Saturday and we can hopefully get that sort out the engine side of the problem.

It looks like I am going to have to build a new exhaust system as it will all be filled with the oil and stuff that came out of the engine. Been looking at several types of exhaust, not sure what I am going to fabricate yet, don't want it to be too loud, but I feel if I exit the exhaust backwards it will be far too loud.

Any pictures of converted vehicles exhausts like suburus etc, wonder if one of those would be quiet enough. Any box can be made to fit with some flexipipe from local motor factors, think its about £23 for 2m and it will take any shape, however would prefare to have a solid fully welded system like my last. I called at my local exhaust centre and they basically said if I get there before the scrap man I can have any sections of exhaust I want as putting bends in exhausts are very hard compared to straights etc.

Will keep posted.

Dickspanner
Crewwy now running a 2.9litre 24V V6 Injection Cosworth motor.Oh the Joy. Happy Happy Joy Joy. Mmmmmmmmm

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Cableguy
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Re: Cosworth 2.9litre in my Crewwy

Post by Cableguy »

Just thought I'd mention that the exhausts on mine just go straight out the back. There's a silencer on each. Custom made out of ss.
It was rediculously loud until I realised manifold gaskets were mullered. Actually quite reasonable now.
Not sure if you'd get away with that setup.

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dickspanner
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Re: Cosworth 2.9litre in my Crewwy

Post by dickspanner »

You got any pictures of the exhausts, as it would be a similar route to mine if I decided to go out the rear?

Cheers

Dickspanner
Crewwy now running a 2.9litre 24V V6 Injection Cosworth motor.Oh the Joy. Happy Happy Joy Joy. Mmmmmmmmm

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Cableguy
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Re: Cosworth 2.9litre in my Crewwy

Post by Cableguy »

Ok, take a couple and post up

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dickspanner
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Re: Cosworth 2.9litre in my Crewwy

Post by dickspanner »

That would be great pal

Cheers

Dickspanner
Crewwy now running a 2.9litre 24V V6 Injection Cosworth motor.Oh the Joy. Happy Happy Joy Joy. Mmmmmmmmm

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Jim Hunter
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Re: Cosworth 2.9litre in my Crewwy

Post by Jim Hunter »

Today finally the harness was out.Sadly we have to cut a section in two (that goes in the front traverse) except from this we remove even the aerial wire ! I will put the cutted wires joined together is it better to solder them. ?

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dickspanner
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Re: Cosworth 2.9litre in my Crewwy

Post by dickspanner »

It really depends pal, which wires you have cut.

It may be a good idea to solder them and heat shrink them so you have a full wiring harness, however if this is a part of the harness you are going to remove, strip and twist and tape may be enough.

Dickspanner
Crewwy now running a 2.9litre 24V V6 Injection Cosworth motor.Oh the Joy. Happy Happy Joy Joy. Mmmmmmmmm

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