2.9 Sierra vs. Ranger Intake Comparison - Side by Side Photos

[PetroleumJunkie412]

Interesting stuff... Makes me wonder a bit why the second set of injectors? Fuel enrichment for forced induction? Entire back up fuel system? Volumetric efficiency thing? Hmmmm

I just didn't see it on the schematic you posted... and had to ask.

FINALLY FOUND IT!!

Prototype Number One: 1987 Ford Sierra RS500 Cosworth

Learn more about Prototype Number One: 1987 Ford Sierra RS500 Cosworth on Bring a Trailer, the home of the best vintage and classic cars online.

bringatrailer.com

"A member of the Cosworth YB engine series, the unit in the RS500 displaces the same 2.0 liters as the standard unit which produced 201 HP in stock, road-going form. Racing versions of those engines developed approximately 370 HP, but faced limited potential thanks to a smaller Garrett T3 turbocharger. Paired with a strengthened block built to withstand increased boost pressure, a Garrett T04 helped the RS500 produce 220 HP, with cars tuned to full racing spec making around 550."

In 1987. In. 2.0l. With 4wd.

IIRC, it was a matter of a simple jumper wire or extra connector to the harness to max out boost control and bring on all eight injectors. So in a few minutes your Sierra went from 220hp to 500+. Ford was eventually forced to quit building them over insurance.

Gee, wonder who Dodge copied with the Hellcat/Demon and the red /black keyfobs...

 

[PetroleumJunkie412]

Motorcraft brand Sierra TPS is inbound. All I have to figure out now is the intake filter(s).

May gasket match the ports. Read on the Ford Europe forums that it helps out same as on Ranger. May hold off though to see a before and after. Will say that it made a huge difference when I ported my Ranger's plenum and lower intake.

Phenolic spacers were recommended as well. Anyone that finds one before I do gets a six pack and a high five.

 

[Bird76Mojo]

You can have your Cozzie's and your RS's. All I've ever wanted was the Supervan.

 

[PetroleumJunkie412]

You can have your Cozzie's and your RS's. All I've ever wanted was the Supervan.

All I ever wanted was a Subaru Justy, but APPARENTLY that's FROWNED UPON in this ESTABLISHMENT.



...jerks.

 

[PetroleumJunkie412]

...it looks a little vulgar.

 

[Ranger850]

you spelled "sexy" wrong...

 

[PetroleumJunkie412]

you spelled "sexy" wrong...

....I'll just say it. It looks phallic.

 

[Bird76Mojo]

 

[PetroleumJunkie412]

So, counting up the vac ports on my Ranger intake, it looks like I have six rhat will need to be carried over (FPR, cruise control, brakes, pcv, charcoal can, MAP) Counting the ports available on the UK intake, looks like I have four available. No worries on that, I'll more than likely relocate the IAT sensor to the aluminum intake, and use the IAT port for the vacuum splitter off the Ranger plenum.

New challenge is a block off plate for that weird hole on the UK intake. No idea what that was for. Guessing EGR.

The six mounting bolts were a challenge as they have to have gasket washers under them. The intake came with five, and not even fastenal had the sixth. Found an eBay seller that sold me.hex head flange bolts that would work, and another that made the gasket washers. Getting closer.

 

[PetroleumJunkie412]

The question is now while I'm waiting on parts... Do I just gasket match port and be done with it? I know I'm going to wind up doing it anyways...

 

[Ranger850]

idk what " gasket match port" means, but DO IT...

 

[Bird76Mojo]

idk what " gasket match port" means, but DO IT...

You basically use the gasket set to mark your two mating surfaces on the parts that will joint together, and using those marks, you open up the ports using a die grinder and different bits and sanding tools.

An example would be where the intake ports meet the cylinder heads. The intake air flows through those ports, and most of the time, the ports don't match up well in size and shape. So you coat the head surface in Dykem (or even Sharpie) lay the gasket down, mark the internal opening in the gasket, then grind the ports in the head to the size of the opening in the gasket by using your marks as reference lines. Then you do the same to the intake ports where they meet the heads. When you're done, the ports in the intake match the ports in the head, both matched in size to the gasket that lay between them.

Left port has been gasket matched, while the right hasn't been done yet.

 

[PetroleumJunkie412]

You basically use the gasket set to mark your two mating surfaces on the parts that will joint together, and using those marks, you open up the ports using a die grinder and different bits and sanding tools.

An example would be where the intake ports meet the cylinder heads. The intake air flows through those ports, and most of the time, the ports don't match up well in size and shape. So you coat the head surface in Dykem (or even Sharpie) lay the gasket down, mark the internal opening in the gasket, then grind the ports in the head to the size of the opening in the gasket by using your marks as reference lines. Then you do the same to the intake ports where they meet the heads. When you're done, the ports in the intake match the ports in the head, both matched in size to the gasket that lay between them.

Left port has been gasket matched, while the right hasn't been done yet.

Second. I usually use a diamond bit and scribe a line like an engraving then work from there. First step is to open with a fly cutter on a dremel, then blend with a rounded cylinder fly cutter, sand with a flap wheel, then sand with abrasive discs/those dremel bits that look like scotchbrite pads. Man o freaking man does it make a difference.

Two identical engines and trucks are on a drag strip with two identical drivers. Only difference is gasket match porting. Gasket match wins every time, hands down. It's a 1%-10% gain in efficiency and power, depending on engine.

Also, if you've watched the YouTube video on my build thread of a highway merge, the truck started making the intake noise it now does when I step on it after porting, didn't make it before. That's the (f**ck your guts) noise.

 

[Bird76Mojo]

Dremel? Step ya game up son.

If you're good with these and have the hand/wrist strength to hold the die grinder from getting away from you, no further sanding is necessary when using these bits in my experience. I used these dozens of times a day back when I was an aluminum fabricator and our QC department was super OCD on surface finishes.

https://goldencoulee.com/collections/top-viewedd/products/1045

 

[Ranger850]

thank you both for that thorough explanation.