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Old 02-20-2013, 11:10 AM   #1
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What I Drive: 2006 Sonic Blue ZX3

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Question Any info on the Cosworth 2.3 280BHP Engine Swap?

Hey everyone! :)

I wanted to start piecing together information and any problems that might arise from swapping the Cosworth 2.3L 280BHP (20001727) Engine into the 2006 MK1.5 ZX3 SES Focus I have.

This is going to take me quite some time to acquire the funds to do the entire swap and purchase. But, basically I wanted to plan out any modifications I make on the vehicle in the mean time to be transferable to the new engine when done.

Obviously there are a lot of parts I would need to rule out completely as there will be Cosworth parts installed on pretty much the entire engine.

The real question is what is there that I can do that they wont be installing automatically.

Also, I'm assuming an engine like this would be race application only and this would not be streetable. If I am able to retain street compliance then that would be nice in that I can drive it to shows and meets.

If not possible then I'll keep this puppy garaged for race days only and buy me a daily after the wife gets our next vehicle.

They install BOLDED, with everything in Underlined Italics is optional.


Engine Matrix
-2.3 Forged Pistons (CR 13:1)
-Cosworth Piston Ring Pack
-2.3 Forged Connecting Rod Kit
-2.3 Big End Bearings (VP2)
-2.3 Billet Crankshaft

Fuel System
-High Flow Fuel Injectors
-Large Capacity Fuel Rail

Cylinder Head/Valvetrain
-Cosworth Ultra Race Camshafts
-Cam Friction Washer
-Ultra Race Valve Spring
-Cosworth Extrude Honed Cylinder Head
-Heavy Duty Head Bolts

Lubrication System
-Modine Oil Cooler
-High Flow Oil Pump
-Cosworth Stage 2 Dry Sump

Coolant System
-Cosworth Large Pulley Water Pump
-Thermostat (82* C) & Housing

Induction System
-Cosworth Roller Barrel Throttle Assembly
-Carbon Fiber Airbox and Foam Air Filter
-Throttle Position Sensor

Exhaust System
-Exhaust Gasket

Electrical System
-Starter Motor
-Ignition Coil
-Spark Plugs (Temp 7)
-Loom Kit
-ECU (Flashed with Base Calibration)
-Calibration Interface Kit

Auxiliary Drive
-Lightweight Alternator (40 Amp)
-Lightweight Alternator Brackets
-Alternator Pulley (64mm)
-Accessory Drive Belt (1,310 mm)

-Lightweight Flywheel
-Spigot Bearing
-Heavy Duty Flywheel Bolt Set
-Engine Lifting Eyes (Pair)
-Cosworth Carbon Coil Cover including Fitting Kit

Engine Assembly and Test
-Cosworth Assembled
-Engine Hot Test
-Full Engine Break-In & Performance Test
-Dispatch Kit


My idea is that I should focus (no pun intended) on in this order of preference.

-Agressive Suspension
-Wheels & Brakes
-Lightening the Vehicle with Carbon & Lexan
Lexan Windows
-Hose Work?
-Competition Radiator?
-Any modifications you guys can think of.

A pretty hefty project to take up on, but time & money are on my side. :)

I'm also looking to see if this would be best as a naturally aspirated engine application or if its possible to Supercharge or Turbocharge the vehicle. I noticed the 13:1 Compression Rating and I would be afraid to do so.


"A mime is a terrible thing to waste." -Mel Brooks
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