Ford Cosworth YB Turbo Tuning Guide

Ford Cosworth YB Turbo engine

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+.

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  1. Camshaft timing belt & tensioner kit Ford Cosworth YB SC1245K
    £74.95 (inc VAT)
    (ex VAT) £62.46

    Part Number: SC1245K

    144 tooth belt. Genuine Gates powergrip belt with INA tensio.... Learn More
    Available From Stock
  2. Wossner steel H section con rod set 136mm: Ford Cosworth YB & Pinto long rod KCR023H
    £717.60 (inc VAT)
    (ex VAT) £598.00

    Part Number: KCR023H

    Available From Stock
  3. Oil seal front cover (used), crankshaft: Ford SOHC Pinto & Cosworth YB FT1067X
    £48.00 (inc VAT)
    (ex VAT) £40.00

    Part Number: FT1067X

    A used front cover in excellent condition. Vapour blasted, r.... Learn More
    Available from Stock (while stock lasts)
  4. Wossner Inconel exhaust valve set 31mm (8 off): Ford Cosworth YB KV9542-E
    £271.20 (inc VAT)
    (ex VAT) £226.00

    Part Number: KV9542-E

    Stock Lead Time Typically 1-3 days
  5. Wossner black nitrided steel inlet valve set 35mm (8 off): Ford Cosworth YB KV9542-I
    £196.10 (inc VAT)
    (ex VAT) £163.42

    Part Number: KV9542-I

    Stock Lead Time Typically 1-3 days
  6. Wossner Inconel exhaust valve set 32mm (8 off): Ford Cosworth YB KV95421-E
    £271.20 (inc VAT)
    (ex VAT) £226.00

    Part Number: KV95421-E

    Stock Lead Time Typically 1-3 days
  7. Wossner black nitrided steel inlet valve set 36mm (8 off): Ford Cosworth YB KV95421-I
    £196.10 (inc VAT)
    (ex VAT) £163.42

    Part Number: KV95421-I

    Stock Lead Time Typically 1-3 days
  8. Kent Cams titanium valve spring retainer set: Ford Cosworth YB using 214N 9\32" stem valves KCVRT06-S
    £167.50 (inc VAT)
    (ex VAT) £139.58

    Part Number: KCVRT06-S

    Stock Lead Time Typically 4-7 days
  9. Bosch Motorsport fuel injection pump: Ford Sierra\Sapphire Cosworth Group A 0580464200
    £198.00 (inc VAT)
    (ex VAT) £165.00

    Part Number: 0580464200

    Genuine Bosch Motorsport 0580464200 (a direct fit replacemen.... Learn More
    Stock Lead Time Typically 1-3 days
  10. Fuel pressure regulator: Ford Escort Cosworth T34\T25 SC532
    £48.00 (inc VAT)
    (ex VAT) £40.00

    Part Number: SC532

    Replacement 3.5 bar regulator, direct fit into the fuel rail Learn More
    Available From Stock
  11. Samco red silicone turbo to header tank hose, Ford Sierra Cosworth 2wd TB165RED
    £18.00 (inc VAT)
    (ex VAT) £15.00

    Part Number: TB165RED

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Stock Lead Time Typically 8-12 weeks
  12. Denso Iridium spark plug: Ford Cosworth YB & RS Turbo IK27
    £10.00 (inc VAT)
    (ex VAT) £8.33

    Part Number: IK27

    Available From Stock
  13. Denso spark plug Ford Escort Cosworth (platinum) & modified YBs PK20PR-P8
    £8.50 (inc VAT)
    (ex VAT) £7.08

    Part Number: PK20PR-P8

    Recommend for all Cosworth YB engines up to approx 350bhp. O.... Learn More
    Available From Stock
  14. Samco classic black silicone turbo boost hose set (3 hoses): Ford Escort Cosworth YBP T25 (with cold side dump valve outlet) 05\94-96 TCS-01\BD(CLASSIC)
    £198.95 (inc VAT)
    (ex VAT) £165.79

    Part Number: TCS-01/BD(CLASSIC)

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Stock Lead Time Typically 8-12 weeks
  15. Samco classic black water coolant silicone hose set (5 hoses): Ford Sierra\Sapphire Cosworth 2wd TCS-04\C-A(CLASSIC)
    £144.95 (inc VAT)
    (ex VAT) £120.79

    Part Number: TCS-04/C-A(CLASSIC)

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Stock Lead Time Typically 8-12 weeks
  16. Swirl pot: Ford Sierra\Escort Cosworth 2wd\4wd satin silver SP1SAT
    £109.90 (inc VAT)
    (ex VAT) £91.58

    Part Number: SP1SAT

    Water swirl pots are fitted as common practice on many race.... Learn More
    No Stock - ordered on demand
  17. Arrow steel H section con rod set, 5.35": Ford Cosworth YB 22mm pin ARROW219
    £1,625.00 (inc VAT)
    (ex VAT) £1,354.17

    Part Number: ARROW219

    Arrow Precision steel con rods are found in almost every are.... Learn More
    Contact Sales for Availability
  18. Wossner forged piston & Wossner H beam steel rod kit 91.25mm: Ford Cosworth YB Turbo 17cc fast road spec long rod K9542D045KH
    £1,351.25 (inc VAT)
    (ex VAT) £1,126.04

    Part Number: K9542D045KH

    Wössner pistons feature a unique PTFE coating on the skirts.... Learn More
    No Stock - ordered on demand
  19. Wossner forged piston & PEC I beam steel rod kit 91.25mm: Ford Cosworth YB Turbo 17cc fast road spec long rod K9542D045KI
    £1,351.25 (inc VAT)
    (ex VAT) £1,126.04

    Part Number: K9542D045KI

    Wössner pistons feature a unique PTFE coating on the skirts.... Learn More
    No Stock - ordered on demand
  20. Wossner forged piston & Wossner H beam steel rod kit 91.5mm: Ford Cosworth YB Turbo 17cc fast road spec long rod K9542D070KH
    £1,351.25 (inc VAT)
    (ex VAT) £1,126.04

    Part Number: K9542D070KH

    Wössner pistons feature a unique PTFE coating on the skirts.... Learn More
    No Stock - ordered on demand
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