What do you do after you’ve built the most powerful road going GC8 in the UK?  You drive it, a lot, of course! 

For those passionate about internal combustion marvels, half the joy – perhaps even more – lies in the intricate process of creation. Countless hours are invested in scouring the vast expanse of the internet for inspiration, meticulously selecting the optimal components, and envisioning the aesthetic masterpiece that will unfold. The journey is often punctuated by delightful detours into the realms of other enthusiasts’ narratives, occasionally veering off into the realm of adorable feline distractions (though, perhaps, that last sentiment is unique to me).

Upon the triumphant completion of the project, a surplus of time seemingly emerges, begging the question of how to fill this newfound void. The answer, elegantly simple, is to embark on the creation of yet another automotive masterpiece. Enter our esteemed and long-standing patron, Stewart.

In the nostalgic echoes of boyhood dreams, Stewart, like many of his contemporaries, harboured a fervent desire for an Escort RS Turbo. Yet, his father’s cautionary tales, born from endless hours welding and repairing rusty old Ford Escorts, dissuaded him from pursuing this dream in his youth. However, time has a peculiar way of reshaping aspirations. Fast forward to the year 2022, Stewart found himself inevitably drawn to the allure of RS Turbos once again, the kids had grown up and insurance premiums were no longer sky high. This sparked a profound itch that could only be appeased by decisive action!

Attempting to alleviate the itch with more than mere calamine lotion, Stewart delved into the world of the RS community, only intensifying the desire. In a strategic move to quell the persistent yearning, he sought out a red Series 2 Escort RS Turbo (coincidently the same colour as his Impreza, accident or not?)– a rare gem in a landscape where enthusiasts guard these treasures with reverence and other offerings available are all rotten. As luck would have it Stewart found one just 40 minutes away from his home with a suspected oil pump failure.  Despite the financial toll, Stew’s wallet took one for the team, and thus, the itch found its remedy. Or so it seemed.

This Escort made its way to our workshop at Enginetuner for a thorough health check. Alas, not everything was in perfect harmony; the engine lay dormant, refusing to spring to life. Rather than succumbing to disappointment, Stewart seized the opportunity to re-evaluate his automotive dream. The notion of a ZVH conversion (A Frankenstein engine built from a Zetec bottom end and utilising the original CVH cylinder head and manifolds) had been percolating in his mind, and this unexpected turn of events served as the catalyst for action.

It marked the release of the metaphorical snowball at the peak of the mountain. As we relayed the unfortunate news to Stewart, he saw beyond the setbacks and embraced the silver lining. After all, when it comes to Stewart’s projects, the adage “Go Big or Go Home” resounds as a guiding principle. The RS Turbo saga had merely reached its introductory chapter, leaving us eagerly anticipating the epic tale that would unfold under Stewart’s discerning and ambitious gaze.

With a 2.0 Zetec block sourced, we got to work building a forged engine capable of whatever we can throw at it. Let’s face it, Stew is known to push the limits when it comes to horsepower!

The engine block, entrusted to our highly skilled engineers, underwent meticulous attention, with precision boring and honing to accommodate the new Wossner forged pistons. Simultaneously, the cylinder head underwent a comprehensive overhaul in anticipation of the reassembly process.

The resultant ‘ZVH’ powerhouse received a series of carefully selected upgrades, chosen to optimise the ZVH build including Kent cams, vernier pulleys, new belts and pumps. To propel the performance further, a stage 3 hybrid turbo was seamlessly integrated to deliver the boost.

Noteworthy modifications include customisation of the front bumper to accommodate the large front-mounted intercooler with our skilled craftsmen meticulously fabricating custom pipework for both the intercooler and radiator.

To enhance drivability, a hydraulic clutch conversion was deftly executed, complemented by the installation of a performance clutch to handle the torque en-route. Recognising the need for modernisation, the dated 80’s ECU was gracefully replaced with a cutting-edge Link Fury X ECU. This upgrade not only facilitated the incorporation of a flex fuel sensor but also enabled the integration of a Toucan display, providing Stewart with real-time monitoring of vital statistics. Our talented technicians crafted a bespoke wiring harness to integrate both modern and retro systems. Cleverly pieced together in a manner where the car can easily be put back to OEM should one ever feel the need. 

Conscious of the heightened power output, a comprehensive brake upgrade was imperative. The antiquated brakes were replaced with a ‘Hi Spec’ upgrade, ensuring Stewart can bring his RS Turbo to a halt with modern efficiency. Additionally, the entire brake system benefited from a set of brand-new lines.

Addressing the handling dynamics, the four-decade-old suspension was gracefully retired and replaced with new shocks and springs, elevating the RS Turbo’s agility and responsiveness.

A wheel refurbishment, coupled with the addition of spacers, not only bestowed an improved stance upon the RS Turbo but also enhanced its overall aesthetic appeal, and the final addition, the jewel in the crown, the ‘built by Enginetuner’ plaque.

Now it’s off to Stewart to run-in the engine before Martyn can work his magic and turn up the wick. Watch this space…

Enginetuner – Performance engineering at its finest.