The biggest and most successful collaboration The motor racing exploits of Ford and Cosworth are well known, but the famous racing partnership also saw Cosworth play a major role in enhancing road car performance for Ford. With road cars running the gamut from eye-catching coupes and family saloons to homologation specials, Cosworth’s engineering prowess created more thrilling road cars.
Established in 1958 by the ex-Lotus engineers Keith Duckworth and Mike Costin, Cosworth made a name for itself by producing remarkable results from small to medium volume engines. Ford-related projects involved inventive airflow enhancements, engine upgrades and in some cases completely reworked powerplants. Over the next decade the cars shown here were an extension of that early 1960s performance-based programme, and the start of the really legendary Ford RS stable.
1. 1963 Ford Consul Capri GT
The first Ford Road car to be subject to Cosworth attention was the elegant 1963 Consul Capri GT. The Capri was to receive Ford’s new 1.5-litre Kent engine, but wearing a few carefully considered extras. The car’s performance was ultimately to be boosted from the original 60bhp to around 78bhp, thanks to the installation of a new camshaft, upgraded carburettor and new exhaust manifold, all designed to coax greater performance from the fairly modest production unit. The resulting Capri GT was set to offer the same concept of sporty style with improved performance without the fearsome 80-something bhp of the more powerful engines on offer.
Consul Capri GT Performance Highlights:
- First Cosworth-tuned Ford Road car
- 1.5-litre Kent engine
- Power increased to 78bhp
- Top speed reached 95mph
- 2,002 examples produced
The end result was that the improved engine was capable of propelling the Capri GT to a top speed of 95mph and to accelerate from 0-60mph in 13.5 seconds – around four seconds faster than the 60bhp 1.5-litre version. It proved that Cosworth’s modestly conceived upgrades had a tangible effect. Although only 2,002 were built, this was a project that achieved rather more than the number of cars sold might suggest. Ford and Cosworth had formed a technical link that would be carried forward into other performance car projects and so the Consul Capri GT proved a significant starting point for one of the most successful engineering partnerships the world of Ford road cars has seen.
2. 1963 Ford Cortina GT Mk1
In 1963, the factory released the new Ford Cortina GT Mk1, which arrived along with its sibling, the Consul Capri GT. The pair utilized similar Kent engine design principles from the factory as the Consul, but Cosworth used a slightly altered Weber carburettor configuration to maximize the potential of the 4-cylinder. The new configuration allowed for 83bhp to power the family saloon, giving the family-focussed car a surprisingly spunky nature, with enough punch to outperform the mainstream Ford range of the day without requiring the development of a brand-new engine.
Cortina GT Mk1 Engineering Highlights:
- Closely related Kent engine
- Different Weber carburettor setup
- Power output of 83bhp
- Top speed of 94mph
- Front disc brakes fitted
First official tests showed that the Cortina GT Mk1 could attain a maximum speed of 94 mph and accelerate from 0 to 60 mph in 13.9 seconds. Slightly larger and heavier body than that of the Capri coupe meant less quickness in acceleration however the improved engine made the car quite sporty for a saloon of that age. Ford was aware of the fact that this enhanced performance required better brakes for the car, hence the GT version came equipped with front disc brakes to cope with the more powerful chassis. The Cortina GT is yet another example of Ford and Cosworth’s ability to make a family saloon more enjoyable to drive.
3. 1963 Ford Lotus Cortina Mk1
The 1963 Ford Lotus Cortina Mk1 was one of the first notable results of the Ford and Cosworth partnership. For some time, Lotus had been using a Twin Cam cylinder head on the 116E engine in its Elan sports car but this still left the unit with a few significant teething problems just ahead of its full launch. Given the internal airflow weaknesses, Cosworth was tasked with refining the engine’s breathing and helping draw out its performance potential. The developed 1558cc unit was then installed in a two-door Cortina bodyshell, producing a light and sporty sport saloon with a great deal more sporting punch.
Lotus Cortina Engine and Performance:
- Lotus Twin Cam cylinder head
- Cosworth airflow development work
- 1558cc engine capacity
- Top speed of 108mph
- 3,304 Mk1 models sold
The 1558cc engine, available in a road-going mode, enabled the Lotus Cortina to travel at 108 mph and accelerate from 0-60 mph in a mere 9.1 seconds. Those were very impressive figures for a saloon of the time, and the excellent engine development only enhanced Cosworth’s reputation among Ford’s own top management. Curiously, Lotus chose not to go to the press with Cosworth’s vital role in improving the flow of air into the 4-cylinder engine. Despite that, the production-ready powerplant was a great success and found eager customers in the showrooms. 3,304 Mk1s rolled off the production line, solidifying the Lotus Cortina’s place in history as a major step in the evolution of Ford’s sportscar lineage and the broader Cosworth relationship.
4. 1968 Ford Escort Twin Cam
By 1968, the two-part airflow development work that Cosworth had been engaged in with Ford was paying further dividends for the manufacturer’s performance cars. When Ford decided that it needed a faster Escort for use in competition, the engineering team decided to use the tried and tested 1558cc Lotus twin-cam powerplant. This was fitted into a diminutive two-door Escort saloon shell and proved a very useful pairing of a comparatively small body with a high-performance engine. The Escort Twin Cam showed how the engineering grounds so successfully explored with the Lotus Cortina could be applied to an additional Ford model with high sporting credentials.
Escort Twin Cam Performance Figures:
- Introduced in 1968
- 1558cc Lotus twin-cam engine
- Power output of 109bhp
- Top speed of 113mph
- Only 883 cars produced
The Twin Cam engine produced 109bhp and enabled the Escort to hit 0-60mph in 9.9 seconds on its way to a top speed of 113mph. The RS only rolled off the production line 883 times but despite the minuscule production run, it marked a crucial phase in the Escort’s evolution as a performance car. With its small footprint and twin-cam engine, the Escort proved to be a viable candidate for the development of future sporting Escorts, most notably the RS 1600 and the generations of sporting Escorts that followed. Most importantly of course, the Twin Cam paved the way for the RS 1600.
5. 1970 Ford Escort RS 1600
Synergising the power of Ford’s first RS-badged hot hatch and new Cosworth engine was the world’s first 1970 Ford Escort RS 1600. Contained within was the all-new 1601cc BDA engine, which Ford’s Mike Hall built up from a Kent iron block with double overhead camshafts and a Formula- racing-derived cylinder head layout. The BDA series’ double overhead camshafts were driven via a toothed belt hence the BDA name for Belt Drive, Series A and its 16-valve designwas a paradigm shift for Ford’s range of road-going go-faster models, combining motor sport competence with street-level fun.
RS 1600 Cosworth BDA Specifications:
- First RS-badged fast Ford
- Bespoke 1601cc BDA engine
- Designed by Mike Hall
- Power output of 120bhp
- Toothed-belt-driven camshafts
The twin-cam also underpinned the Escort RS 1600. ‘We would be able to use the 120bhp twin-cam to give that aggressive, distinctive sound of that period, which we all became familiar with for years, on to our Escort cars. It could do 120mph, and accelerate 0-60 in 8.9 seconds. And performance was backed up by strong links to Cosworth’s 1599cc FVA Formula Two single-seater engine, confirming the motorracing inflection point that had gone into the development of the Escort’s twin-cam. The RS 1600, in other words, was more than another Escort with an engine, more than yet another quicker Escort, it forged a defining performance identity for Ford’s RS range.
6. 1975 Ford Escort RS 1800
The 1975 Ford Escort RS 1800 was developed with competition and homologation requirements firmly in mind. Its construction involved an unusual process, with Ford taking 1600 Sport bodyshells to its Aveley facility, where they were stripped and reinforced before receiving Cosworth’s BDA engine. Later examples used RS Mexico shells instead. Under the bonnet was an enlarged 1834cc development of the twin-cam powerplant, producing 115bhp in factory specification. This combination gave the RS 1800 a stronger foundation for both road use and the demanding conditions of rally competition.
Escort RS 1800 Engineering and Performance:
- Reinforced 1600 Sport shells
- Later RS Mexico bodyshells
- Enlarged 1834cc BDA engine
- Factory output of 115bhp
- Up to 255bhp in competition
In normal trim the RS 1800 was capable of 112mph and a 0-60 time of 8.3 sec. but the car’s rally potential far exceeded even those figures. A 2-litre version of the Cosworth engine could be built with up to 255bhp and, armed with the latter, the Escort was something to be reckoned with in the hands of top rally drivers such as Ari Vatanen, Hannu Mikkola and Jimmy McRae. Their exploits played a significant role in the Escort RS 1800 establishing itself as an all-conquering competitor on the world rally stages and Ford’s most successful competition car thanks to its combination of a strengthened bodyshell and high-powered Cosworth mechanics.
7. 1984 Ford RS 200
The 1984 Ford RS 200 was built specifically for the extreme Group B era of the World Rally Championship. Unlike more typical high-performance production vehicles, the RS 200 was an entirely engineered racing version built around the demands of the Group B cars. Rather than being a traditional performance vehicle, the RS 200 name was the figure of cars required to meet homologation criteria the variant in this case being an 1803cc Cosworth turbo BDT mill underneath the imposing rear clamshell. A development from the RWD RS 1700T project, the RS 200 was a true high-performance car.
RS 200 Powertrain and Competition Figures:
- Purpose-built Group B machine
- Mid-engined layout
- 1803cc turbocharged BDT engine
- 250bhp road-car output
- Up to 650bhp in rallycross
Road-going models boasted 250bhp, while full works rally cars were even more impressive at 450bhp. The demise of Group B, however, meant the RS 200’s time in rallying was cut short when officials decided to ban the class after the 1986 season. Luckily, the car still had a rallycross career ahead of it, during which it employed the larger-capacity 2.1-litre Cosworth BDT engine that could develop up to 650bhp. While this was more a statement of how potent the powertrain was, the RS 200 took its final steps in competition.
8. 1985 Ford Sierra RS Cosworth
The 1985 Ford Sierra RS Cosworth represented a milestone in the collaboration since it was the first production car from Ford to display Cosworth’s name on the badge. The three-door was created after Ford motorsport head Stuart Turner required an appropriate competition platform to replace the V6-powered XR4i. The answer came with Cosworth’s all-new 16-valve turbocharged YBB engine signalling the transmission of specialised engineering to a production Ford. The powerplant used Ford’s familiar Pinto engine block as its basis but its capacity was expanded to 1993cc and turbocharged.
Sierra RS Cosworth Engine and Performance:
- First Ford with Cosworth badge
- 1993cc YBB turbo engine
- Based on Ford Pinto block
- Power output of 201bhp
- Top speed of 149mph
Officially rated at 201bhp, the turbocharged Sierra RS Cosworth could hit 149mph and jet from 0-60mph in just 6.2 seconds. It was a genuine performance car contender, however, thanks to its aggressive aerodynamic design. Its large rear wing was one of the first design elements that would be recognisable among the crowd, and the exterior’s serious appearance was a clear hint at its competition-bred mentality. Originally engineered to give Ford a competitive and motorsport-ready foundation to work from in racing, it proved a popular road-vehicle for drivers also seeking a true high-performance model.
9. 1990 Ford Sierra Sapphire RS Cosworth 4×4
The performance equation evolved even more with the 1990 Ford Sierra Sapphire RS Cosworth 4×4, which paired the Cosworth powertrain with four-wheel drive. It’s widely recognised among enthusiasts as the best of the Sierra RS Cosworth range, thanks to superior handling at speed and better grip. The chassis gained an MT75 five-speed manual transmission and a more sophisticated all-wheel-drive system, which changed the car’s handling through high-speed bends and added more stability. Cosworth increased power to 220bhp to offset the weight of the extra mechanicals needed for four-wheel drive.
Sierra Sapphire 4×4 Technical Highlights:
- Four-wheel-drive configuration
- MT75 five-speed manual gearbox
- Engine output of 220bhp
- Green-headed YBG engine option
- Enlarged intercooler for efficiency
Two versions of the engine were supplied for different markets. A higher specification green headed YBG unit was supplied to meet the more severe emissions standards imposed on the US market while the red headed YBJ version was supplied elsewhere. A large enlargement of the intercooler throughout the development of the engine meant that boost pressure did not decrease due to more efficient operation of the turbo with the associated benefits in terms of overall performance of the car. Coupled to these changes was an upgraded transmission and further traction through the use of four-wheel drive to produce an exciting high-speed package with excellent all-year behaviour.
10. 1992 Ford Escort RS Cosworth
The Escort RS Cosworth was developed by Ford in 1992 to give the Blue Oval marque a foothold in the world of 1990s international rallying. Rather than develop a traditional Escort, the car was derived from a modified 5th generation Escort shell coupled with shortened running gear from the Sierra Sapphire 4×4. Bland it was not – the Escort RS Cosworth was easily spotted from a distance thanks to bulging wheel arches, a large front splitter and a huge whale tail rear wing. Under its bonnet was Cosworth’s turbocharged 2.0-litre YBT engine which developed 227bhp. Using a Garrett T03/04 turbo, the Escort could attain a maximum speed of 137mph and could sprint from 0-60mph in 5.8 seconds.
Escort RS Cosworth Performance Features:
- Modified fifth-generation Escort shell
- Shortened Sierra Sapphire 4×4 running gear
- 2.0-litre YBT turbo engine
- 227bhp with Garrett T03/04
- 0-60mph in 5.8 seconds
Initial runs of the Escort RS Cosworth were very slow to spool up, so much so that owners had to drive it more aggressively to get the most from the engine. Ford remedied this in 1994 by fitting a smaller Garrett T25 turbo, which dropped peak output from 227bhp to 222bhp but massively increased response and livability without compromising top speed. A more responsive car that was simpler to drive was a desirable development, which of course has not stopped the Escort RS Cosworth becoming one of the most iconic homologation-special performance Fords of the 1990s thanks to its ultimate styling, formidable turbocharged engine, and specialised running gear.
