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Arguably, the hardest part of boosting the CVH is the turbo manifold. Simply put, no one makes a good manifold. In this post, I'll break down the different manifolds for all of the new people, so that they can get an idea of what can be run with what, and how.

Stock Escort EXP Manifold

These manifolds are found stock on turbo EXP's from the late 80's and can be difficult to locate. The flange is a standard IHI flange, and allows a VJ-11 to be bolted to this manifold A hybrid, fast spooling, high flow turbo can be built form the hot side of a VJ-11 and the cold side and centersection of a Thunderbird IHI turbo. The port spacing is dead on and the correct "D" shape for the CVH head. The problem with using this manifold is the turbo comes into contact with the clutch slave on the second generation and up cars, requiring the slave to be modified or moved. Below is a picture of the manifold on a first gen car.



Escort RS turbo manifold

This is the stock manifold on the MK3 Escort RS turbo from the UK. The engine is factory turbocharged, and is a CVH, but the port shape is round, instead of D shaped. This manifold is forward facing, and uses a standard T3 flange, enabling any T3 flanged turbo, even a hybrid T3/T4 to be used on the manifold. Most likely, this manifold will need to be imported from the UK unless you happen to be lucky enough to find one in the states. The RS turbo gaskets can be made from a set of gaskets for a 4.0L SOHC V6 engine.



Fiesta RS Turbo manifold

To my knowledge, no one has attempted to use this manifold on a USDM escort, but, it has the same port spacing as an RS turbo manifold, with one significant difference. The flange is for a T2 class of turbochargers. Pictures and information on this manifold is difficult to find.

JGS log manifold

JGS tools www.jgstools.com sells a log manifold, or manifold kit for the CVH engines. The kit comes with a pre ported flange, and schedule 40 weld LS and Tees. It can either be assembled by the buyer, or by JGS for an extra cost. The manifold is very robust, and properly welded, should not crack. Since it is a log, it does have the characteristic lack of good flow, but the compactness and ability to mount any turbo at any angle are major draw points. Below is a 3d modeling of the manifold.



DSM manifolds

The port spacing on the 4G63 turbo engine is spot on for the escort, with the problem of the stud pattern being different. A stock 4G63 manifold can be redrilled for the escort pattern and then bolted on the head, but there is a significant difference between the escort port and the DSM oval port. The draw of the manifold is the cheap price, abundance, and no need to move the clutch cylinder. Aftermarket tubular headers for the Mitsubishi can also be used, with the advantage that the flange can be cut from the tubes, and a new one, from JGS tools welded on in its place, making the manifold bolt on to the escort. Because of the wide variety of aftermarket options for the DSM, the headers can be found for MHI turbos, as well as Garrett and other varieties. The stock manifold supports T25/14b/16G/20G and equivalent MHI flanges. Below is a picture of a stock second gen DSM manifold. The second gen eclipse manifold is the preferred manifold over the first gen, due to a different metal composition, leading to reduced tendency to crack.



Miata turbo manifold

The miata turbo manifold is much like the eclipse manifold. It has the same port spacing as the escort, but has an oval port like the DSM, requiring a header to be reflanged, or a manifold to be ported. Both will need a new stud pattern drilled. In my experience, it is better to sell the manifold and buy something more appropriate, since cast manifolds for a miata are worth significant money. If you happen to have a cheap Ebay turbo manifold, reflange it, and run it! Below is a picture OF a Bell Engineering Group cast manifold. I have since sold this manifold, and used the profits to pay for the following manifold.





Custom

There is no end to what can be done custom. The best, however would be stainless steel, or heavy mild steel. Below is the start of my custom schedule 40 header. It will end up being utra compact, with a forward extrusion of 2.5", and a downward extrusion of 3.5" making it more compact then an RS turbo manifold from an escort. Being made of schedule 40, it will resist cracking and should run from quite some time.








 

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Josh_LX said:
The second gen eclipse manifold is the preferred manifold over the first gen, due to a different metal composition, leading to reduced tendency to crack.[/img]
 

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but will the first gen work?? im asking cause theres an eagle talon tsi 1st gen so i could possibly go pull the mani if its in decent shape.
 

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forgot to put in there that its at my local junkyard lol......sorry for the tripple post
 

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Discussion Starter #6
yes it will work, but there is a 90% chance its cracked. Sooner or later, all 1st gen styles will crack.
 

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manifold

hey!! i made a sticky i see! thats my 1st gen pic,COOL.the only thing i have to add is that you can buy a ebay stainless manifold,cut off the ears on the bottom of the manifold ports and reweld 3 back on with stainless welding wire in any mig.It welds like butter and i even welded the sides of the manifold ports to better match the escort gasket.here is a link with both old and new ,manifold/turbo setup.It looks direct fit and didn't take me that long to do.I went top mount but it will work bottom mount too!!Here is a link to the best picture of the manifold(old turbo vs new turbo)
http://www.ssw-online.net/winslow/bg_img_3229.html
here is the link to the progress on the BIG turbo install:
http://www.ssw-online.net/winslow/index.html
I did have to mount the alternator where the a/c mounts but it was easy.
 

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jd_91pony said:
I would like to see a good picture of the down pipe and intercooler piping for the turbo on the DSM manifold since is used upside down.



Hey Josh, remember the Zx2 has the same port spacing as the CVH to. I think with some redrilling the Focus shorty and VJ-11 can be bolted up.
 

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yeah, I was wondering exactly which manifolds would bolt up to the zx2 2.0? I'm going to the local j/y tomorrow to look around...A turbo would be fantastic! lol...any pics?
 

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Ghostzx2 said:
yeah, I was wondering exactly which manifolds would bolt up to the zx2 2.0? I'm going to the local j/y tomorrow to look around...A turbo would be fantastic! lol...any pics?
The only manifold that you will find in the junk yard that will "bolt up" to a Zx2 that could be used as a turbo manifold, would be the OEM Focus shorty manifold. But even then you'll have to drill the cat flange to hold a turbo.
 

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what about what im running, the stock manifold, with a low profile billit adapter and a smaller turbo such as the vj-11. downfalls- limited to small turbo, stuck with the stock cast manifold, cost of making the adapter
upsides- can easily swap back to stock without even having to unbolt manifold, manifold is already on the car, just need an adapter...stock egr, o2 sensors still functional. No need to relocate anything-pcv, slave cylinder, etc.
-Justin
 

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ur pcv needs to be changed or rerouted..........u dont have a clutch slave so that should be it.

anyone know what needs to be movedfor use of the rs mani.........i think the PCV can be stock, im wondering if the A/C can stay.......it looks like its enough room in there for it to stay
 

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Here are some picture i took of my mitsu 4g63t manifold i fit to my cvh,Here is the pictures of the gasket compared to the manifold reworked to fit:

here is a picture of the manifold mounted on a head:

here is a picture of the manifold on a engine with a turbo:
 

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on an automatic CVH escort, the PCV tube needs to be addressed...and the stock internal wastegate acuator hits the shift linkage ... at least on my 95 it does.

so im using springs for my wastegate.

other than that, and modifying the EXP downpipe to fit under the oil pan correctly..

i have stock AC still, power steering, all emissions except EGR..
 

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good ?^ talk to pony express, he just boosted a 1.9 auto. They are pretty similar. The automatics are a lot bigger, but also lack a slave cylinder which is right in the way of the exp and rs manifold.
-Justin
 
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