£5000 COSWORTH ENGINE FULLY STRIPPED ** IS IT SCRAP?? **

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A Few words on the Cosworth engine from
www.burtonpower.com
An incredibly famous engine, the Cosworth YB Turbo actually began life in 1984 as a N/A Cosworth YAA concept. However, the turbo version was launched in the 1986, 3 door Sierra with 204bhp. The infamous RS500 version of the same car followed in 1987 with 225bhp, a bigger T4 turbo, eight injectors (only four connected) and an engine designation of YBD.
Perhaps the most plentiful Sierra, the Sapphire hit the roads between 1988-89 with a 4x4 version being produced from 1990-92. The engine was subsequently available in two versions for this latter car - The YBJ, which incorporated many of the RS500 motorsport type revisions, plus the green cam covered YBG, meant for the US emissions sensitive market. This had three cats, closed loop lambda control and ran on 95 octane unleaded.
Finally the Escort Cosworth took over from 1992 with the big turbo YBT engine, featuring a T34 and four wheel drive, whilst the series came to a halt with the introduction of the T25, small turbo Escort between 1994-96. This also featured Ford EEC IV management, with wasted spark ignition, twin coils, a different series of injectors and a unique black cam cover.
The most common engine is the original YBB (3 dr and 2wd Sapphire), which can be easily tuned with chip and turbo modifications to increase the boost level. However, the 4x4 head is the ideal base since the early type has less water jackets and is susceptible to blowing head gaskets with serious hikes in boost.
To begin with, you’ll need to upgrade the actuator to -31 (dash 31) type and upgrade the management chip to increase the fuel and boost level too - this will typically be to around 270/280bhp. We would recommend that you also fit a good stainless exhaust such as our Mongoose range, plus a K&N filter.
After that stage, you need to swap the injectors for 803s - commonly known as Dark Greens. To this you’ll need a different chip again, plus a 3-BAR MAP sensor to up the boost to 19 PSI (1.3 BAR) resulting in approximately 320-330bhp.
Beyond this level, we’d recommend fitting a Group A or multi-shim head gasket and for extra security in high-boost applications, and an ARP stud and nut kit.
However, around this level, the standard Garrett T3 turbo will have reached its limit although there are now several paths to take in turbo choice. These though are always a trade off between turbo lag and driveability - hence why going straight to a T4 isn’t always a good move. Popular choice is to fit an Escort T34 or a hybrid T3 along with a larger intercooler. T38’s are also available although these aren’t an off-the-shelf Garrett unit and are seen more as a hybrid. You should see power potential with this to around 460bhp, whilst the T34 will give you power to around 380bhp.
At this point - and especially if you want to use a T4 with power potential to the touring car levels of 540bhp - the engine needs to be purpose-built to suit. The reason is you’ll need extra head work in terms of porting, different cams (although BD14s are the limit on the street), lower compression ratios and long stud conversion. The trick is making the most of the unit whilst producing power without huge amounts of lag. Once you get to this stage, we can advise you on the best way forward, depending on the type of engine you have.
A different route, and still popular way to tune the YB, is to return it to the original N/A application, which involves raising the compression. For this, we stock Accralite forged pistons to increase the ratio to as much as 12.5:1 although they can be machined to lower the CR since they have raised crowns for this purpose.
On top of this modification, the head needs the ports seriously opening out and for ultimate horsepower applications, larger valves installed. The cams too need swapping for non-turbo profiles although they aren’t designed to work with the standard YB hydraulic lifters and therefore need converting to solid lifter type.
The bottom end is fine for this type of aspiration since the rods and crank are both steel. We would recommend however, that the rod bolts are upgraded for high-revving applications. For ultimate power though, we also stock steel H-section rods. Lastly, you will need to swap the turbo inlet manifold for a twin DCOE type allowing either 45/48 side draughts or throttle body fuel injection. In this form, you should be able to achieve in excess of 225bhp+.

[@rabmc]

Watched every second of that, enjoyed the close ups and the sound of guy doing his work in the garage uninterrupted and also the birds tweeting in the back ground. Look forward to the progress on this, must be extremely satisfying and exciting doing this.

[@Adam151082]

Thanks Rab

[@thebouncingball4747]

This rebuild could push your channel more than you ever have dreamt Adam. Who needs music when you have the spring birds chirping away. Love the old school rip down m8.

[@michaelsilcock7933]

Absolutely Brill,no stupid music,no sped up time lapse just genuine engine strip..thanks mate

[@powershed]

loved the tweety bird background ambience mate! 🙂

[@lionatelier]

I’m a Mercedes technician in Australia and really enjoyed watching every second. Very hard to find a full tear down of a YB. Thankyou so much.

[@brettwilliams5594]

Nice to see just a man in his garage restoring something that is no longer made. I'm just hoping for a Kawasaki rebuild next time. Nothing better than a geordie saying Kawasaki.

[@Adam151082]

Cheers Dirk, I might have to buy a Kawasaki so I can say it more often 😂

[@theyarenthere]

Kwikasfuki

[@sqwidink1]

Howay kawi man

[@ChrisJones555.]

@@sqwidink1 lol

[@danielclazey1512]

Just as long as you don't get conjunctivitis!

[@LickyDischarge]

This was both interesting and relaxing to watch. Thank you Adam 👍🏻

[@davidsimpson9849]

This was pure therapy Adam brilliant mate I can't wait to see this all rebuilt looking better than new 👍

[@Strukkie]

I'm no Paul Linfoot but I would say that's looking pretty good and no real big surprises! Keep it going Adam!

[@chrisdykes9268]

One of the best videos I’ve watched on KZbin Great camera work and very informative Looking forward to the next instalment Cheers

[@bobdabanks]

Had the same feeling as most Adam found it relaxing to watch. This is going to be an interesting build looking forward to the next installment. Great content as always 👍

[@fatcat2398]

That was bloody brilliant Adam , liked the way you filmed it too , can't wait to see more of this engine.

[@mikematthews2k181]

Another fantastic video Adam 👏 I definitely think the engine had some issue's but it's all there and can be fixed 👍 No snapped bolts is always a good sign 🙏

[@johnchadbone]

Lovely, and that garage must be lovely to work in, here the birds singing away, the smell of oil and petrol. Good times

[@shineyboots]

The most relaxing and satisfying half hour i have had in weeks. More please, PS You've got some really quality tools in that kit.

[@MrJasjoiner]

I can't believe i just sat and watched someone take and engine apart haha but i was genuinely intrigued by every step. Well done Adan cant wait for the next instalment of COSWORTH internals.

[@damiantaylor7993]

That was really good to watch, you showed pretty much everything that is involved with a tear down, clear and informative Adam, well done 👍 on another good video!

[@5678niall]

Looks a better engine than I expected. Big respect for taking the gamble. It was just a shame it was rebuilt by a guy with access to a lot of silicone and no access to KZbin ❤

[@user-lm6vo2uk7v]

Adam I have been watching you for some time now and always enjoy your content but never comment however on this occasion I felt I had to as this was the best of yours so far and can’t wait to see the next ones. Keep up the great work !!!

[@ryanjagger7609]

Probably your best video yet Adam, Awesome. Wouldn't worry too much about the silicone, I reckon someone along line just cheaped out with new gaskets and washers etc . I'm sure you will do a top job can't wait for next update

[@bengriffiths2224]

Great video Adam, nothing more satisfying than the sound of cracking bolts and chirping birds. No snapped bolts is a positive sign this will be a good build 👍

[@s19lun]

Great video Adam. Watch you from day one and must say the improvement of the videos and shots and production is amazing.

[@patrickquinn9826]

Great video of an engine stripdown and good to see someone taking a risk for a change. I hope it works out well for you. You're videos are class.

[@Adam151082]

Thanks Patrick 👍🏼

[@Jim_M_75]

Really enjoyed the video, just the sounds of breaking the engine down, nice on Adam. Looks like you may well have got yourself a long block still at factory specs which will be cracking.

[@martinclarke9174]

Must have had a coolant leak at one point hence the silicone around the thermostat housing looks like radweld residue aswell 😮 glad someone is rescuing it keep up the good work 👍

[@tekglitch4484]

ASMR YB Build. Great video. The background ambience made it really quite pleasing to watch!

[@simocreations]

A lot of work gone into videoing this mate. Next level this man ❤

[@R55LSD]

Love the new format makes really intriguing viewing look forward to the next one.

[@harshithsadhana7475]

Finally, we can learn about the legendary engine

[@gdfggggg]

I really enjoyed this. I’m an ex mechanic (qualified, I’ll have you know 😂). I wacked it on with me earbuds and ten minutes in I fell asleep 👀. I think the birdsong in the background, along with the mechanical bits and bobs was like heaven for me. This is my new mental health vid, ha ha. Cheers bro.

[@paulgrant5169]

Kept looking outside to see where the birds were. Great video.

[@jordo3]

Great bit of content mate. Looking forward to the next installment 👍👍

[@2strokecherry]

Look forward to seeing the rebuild

[@tonybilco1317]

Loved this video cant wait for next instalment and finished result..remember when I was a young mechanic rebuild a pinto 205 block 2litre very much like this for a three door Sierra I loved that car wish I would of still had it engine ran like a dream..keep up the great channel Adam ❤

[@theoriginalwallace]

Looking forward to seeing the rebuild, Adam! I sold my 205 YB minus ancillaries & my spare bottom end for £3900 last year. They both needed machine work & the cost was too high for me. That's why the Viva now has a 4.6 Range Rover V8! I've still got various bits for sale including a brand new Smith & Jones Holbay-Ford replica cam cover that was super expensive! Also a 2wd T5 gearbox that needs 3rd synchro if you know of anyone needing bits. Cheers. Leigh. Edit: someone's gone overboard with the silicone! Get yourself some Hondabond 4 for the rebuild... it's the best stuff & you don't need more than a thin bead on the centre of each face.

[@hands197]

Very relaxing to watch. Top work 💪 Cant wait for the next 1

[@JapsDmz]

Who else thought that last plug was gonna shear off...?😂 I literally held my breath watching hahahaha

[@peterthornton2396]

Oh mate I miss my old cossie days. Had two saffs and an escort cossie. Ran the the saffs on a TT T38 I actually ported the inlet on one of the heads using a 26mm ball bearing to measure! Spent weeks cleaning it up. Sincerely miss those days. Enjoy mate

[@topcat01]

Great video Adam, really enjoyed it

[@gizz1777]

Great video mate and lovely back drop of the cossies 💪👌

[@seanhammond4527]

Gotta be the best KZbin channel on here at the moment cracking videos just get better and better

[@scottgilchrist5659]

Could watch a hundred of these videos, brilliant work!

[@alexirving1251]

Enjoyed that Adam, like a video Haynes Manuel, look forward to seeing more of this build👍

[@series1RS6]

nice detailed break down, i enjoyed every second of this.

[@welshtony1]

Just watched the collection and this video in 1 sit in. Really enjoyed this tear down.

[@nickwhitney1534]

Thanks for sharing. Nicely edited.👍

[@simonp75381]

Great video and filming, you've had a good buy ! Keep up the good work.

[@blacky0121]

TBF! It was very satisfying to watch the breakdown of a cosy engine 😊

[@bazji]

Great vid Adam. Feared the worst watching your first vid buying the engine. But glad to see there doesn’t look like major issues with it. Can’t wait for the next one now. Well done.

[@In_memory_of_Dad]

I truly hope this goes well for you Adam lad and that its not a pile of scrap but a Cosworth engine worth saving!! Good luck brother I really hope this goes your way 👍🙂👍 Regards, John

[@jameshope524]

It will be a belter when its all done adam m8 ,lobe all your videos, always loved fords

[@kevinsimpson4278]

Class mate, not mechanically minded one bit, but been watching your channel a while , good luck with the rebuild 👍

[@tommylloyd1952]

Camera and editing skills are definitely improving mate. Really enjoyed this strip down video keep up the good work buddy. Top content👌🏽

[@dominiclund9236]

I've re built/ built a few cosworth engines by just going at it as u are, very interesting watch and bring back memories, 2014 i built the engine in my escos and its still going 👍

[@brianearl7358]

brill video adam , learnt alot , my taste for cosworths is reigniting

[@rs2klee]

wow all the memory's come flooding back, loved this and well done, look forward to what you do with it :) im sitting here watching and know every single bolt.. even when they were sitting in a box of parts my son would go what bolt is that for, and like a train spotter on heat.. id go its for this or that, my son just looks and thinks wow :) built a few cossie engines back in the day my last one was 387bhp on stage 3 2wd. looking at this engine and how dirty and worn things are will look stunning again with some good tlc and elbow grease :)

[@simonhutton1]

We love your youtube Adam ! 👍 Great work mate top viewing. 👊

[@tommysmith4088]

Really enjoyed that, Can't wait for next one.

[@Lukeashley2323]

Spot on that mate was a great watch as mentioned quite relaxing and interesting looking forward to the next video keep it up 😉👍👌

[@catxls1835]

A quick crank grind, and with a plasti-gauge measure up for some new bearings!! Great video as always Adam.

[@andrewjones4285]

Really enjoy your content. Just a guy having a go like the rest of us do. Love the fact it’s all Sierra RS Cosworth based!

[@torepedersen4056]

A good tip is to loosen all pulleys while the fanbelt and timing belt is still attached and tightened on these engines.

[@davidryan9342]

Man that was relaxing Best of luck Adam

[@gandhi1078]

Simple vid yet so satisfying 👌🏻

[@DavidSmith-mf8ik]

that going to look like a work of art when done .well done Adam 👍🏻👍🏻👍🏻👍🏻👍🏻

[@mlowbridge2988]

He must be concentrating,hardly ever said a word.great video

[@seanpollard5254]

Hi Adam pleasure to watch great video nothing to horrible to worry about keep up the great work 👍

[@DeanCarr]

Love your video's Adam you will end up a Cosworth expert after this engine is refurbed, keep up the good work

[@chrishull4174]

Hi Adam that’s one of the most satisfying videos I’ve watched in ages. Very interesting 👍🏻

[@scope5545]

loved the strip down, i miss working on my old fords, i had a mk2 escort van with a xr2i lump in it kent cams and enjoyed rebuilding that with my dad good fun and good look with your rebuild.

[@raljix1566]

Dude, bloody impressive work!

[@scousehousemaffia4289]

Well Adam if you was wanting big power all that sludge is nothing to fret about probably need everything changing an machining but I can see ya white board getting full quite quick😮

[@elliottierney2407]

Love your videos man .. much appreciated

[@Adam151082]

Cheers Elliot

[@Yogevoo]

Hi Adam great video as always and I've learned a lot there and enjoyed it, love the jubilee clip around the puller legs, I've never thought of that but will defo be using. Looking forward to seeing next video, tbh I did miss your commentary compared to usual videos but great content 😊

[@razorrs25]

Great for the channel this project Adam!

[@Fluffonamission]

Absolutely brilliant to watch this making a good afternoon great 👏🏻

[@catxls1835]

I think that water in the oil is from the plug sockets being open as it's grey. It would be mayo coloured if it emulsified, which is a good sign. The crank also turns by hand and looks smooth so hopefully the crank is ok!!

[@martech3596]

Nicely done mate 👍🏻

[@markprior6009]

Amazing I used to work at Cosworth Castings in Worcester in the 90’s lol. How could someone be such a cheapskate to use silicone on a fantastic piece of British engineering? I’m so looking forward to a rebuild video. Lots of machining and upgrades I suspect? Great video fella 👍🏼👍🏼

[@PeaceDroneAerialVideo]

Enjoyed this video. Keep up the good work.

[@andyhardy322]

Good job there most people would take it to a garage looking forward to this build

[@DJSvenNo1]

I found that relaxing to watch, thanks for sharing

[@tdoteva4973]

Love this content keep it coming

[@alxgu198]

Nice one Adam, now we can all play along at home with our spare Cossie engines 😂👍

[@byronmills5952]

Very enjoyable video. That engines been sat for quite a while by the looks of it - obviously it's had more silicone implants than Katie Price!! It should however rebuild quite nicely. I think the gunged up coolant passages are due to a history of mixed incompatible red and blue antifreeze crystallising and solidifying. Looking forward to further progress! 👍👍

[@mykehyslop198]

Best of luck with the project mate.Subscribed

[@ThomasDoubting5]

Was really relaxing viewing with the birds singing in the background , look pretty straight forward engines to strip , hope it's a good un for you .

[@jeffshaw4553]

Brilliant Adam love it well done was good to watch glad it’s looking good 👍🏽👍🏽👍🏽

[@johnpells5992]

Great video Adam , really enjoyed that , definitely had some issues what with the condition of oil and coolant , the mains didn’t look ok to clever , but all serviceable , looking forward to next episode good luck buddy 👍

[@Scott-oi4go]

Very therapeutic was falling asleep 😴 😂 the birds singing. As well in the background

[@dacco2]

Nice one Adam, looking forward to the follow ups on this.

[@johnhaggerty4257]

Best way to learn Adam. Well done you. Not looking too bad at all.🙂

[@boydiedj3718]

Brilliant vid. Loved the way you filmed this. Glad it wasn’t ruined by shite music and the sound of the birds worked brilliantly. Can’t wait to see more 👌

[@nrud2121]

Brilliant vid fitted perfect with the topic on hand .

[@MrCarrera28]

Great video, thanks for sharing!!

[@robertstirzaker767]

Awesome video Adam, really relaxing to watch. Yeah sludge not very promising but if anyone can, You can mate. 👍🏻

[@garyguest1885]

Spot on mate can’t wait to hear it start 👍🏻 I’m amazed you didn’t turn it over manually before laying out 5k for it tho ..

[@micktre7608]

That's one thrashed engine, good luck with it mate.

[@AndrewSmith-ph5rv]

Possibly some of your best content there enjoying this video.

[@WelshDave76]

Everything is mostly dry too.. I'm liking this! 👌