Cosworth Stage 2 Install w/Dyno, Pics, Videos, Impressions

[6-Shift]

Can't wait to see this thing in person Pete!

[enigma]

Originally Posted by 350matt

if you're getting a lean signal combined with the noise have you checked all round the injector seals ? as these had to be moved over between manifolds

best way to find a vac leak is to spray butane / cigarette lighter gas carefully around each possible leak path as the engine pulls it in as fuel and will rev up if thats the source of the leak

Thanks Matt! Cosworth recommended looking there as well.

I'm going to try and get to it tomorrow, but it will be Wednesday at the latest.

I will say this. Thompson @ Cosworth USA has been incredibly helpful. He's been in constant contact with me since I reported the issue to me and has been trying to help troubleshoot from across the country. The customer service has been absolutely fantastic. He has put me into contact with one of the Senior Development Engineers who is working with me to try and sort the issue out as well.

I can give nothing but high praise for the kit. While this little hiccup is frustrating, these guys have been on their A game since day one with the assistance.

If I can get this sorted this week, I'm going to try and hit the dyno on Thursday, so stay hopeful, internet world! That's the last piece in my puzzle before compiling the video I've taken and making something useful.

[JerryIII]

I will second what great service they provide. Chris is very good and gets thing done. Once you get it running smooth you will love it. Just burnt a hole in my #2 piston. waiting to get it rebuilt.

[enigma]

Originally Posted by JerryIII

I will second what great service they provide. Chris is very good and gets thing done. Once you get it running smooth you will love it. Just burnt a hole in my #2 piston. waiting to get it rebuilt.

Holy crap Jerry! What in the world happened?

[JerryIII]

not to sure what the cause was. In the process of a rebuild.

[Pat]

Originally Posted by enigma

That'd be awesome man! We could always use more 86 track rats around here.

Hey guys, I live in Denver, but will be in Wichita on the 8th for a lunch meeting. I know it's a long shot, but is anyone up for an early afternoon beer that day? I have to be in KC by 5:00.

[350matt]

Originally Posted by JerryIII

not to sure what the cause was. In the process of a rebuild.

Sorry to hear that Jerry

what fuel was it running on? Or any signs of low fuel pressure before it had the issue?

[JerryIII]

91 running map 1 and DW 65c fuel pump

[350matt]

hello Jerry

I take it map 1 is cosworths' low octane 91 ( would be 95 in the UK) map ?

do you have any ECUtek logs of the car running?

[JerryIII]

no logs

[350matt]

Thats a shame about no log data,

were you low on fuel at the time? as I know these cars can struggle with fuel pickup at anything less than a 1/4 tank of gas

one other thing is I've heard the DW65 pump isn't that reliable?

especially if there's any ethanol in the fuel - I'm not talking E85, just the 10% thats quite common in pump gas these days

however these guys do an E85 pump

http://asnuusa.com/ASNU92-FP330E

so might be an idea to swap?



cue loads of people now saying DW 65 is the best pump ever and they have fitted onto every car they own.....

[enigma]

Well, it looks like my problem may be solved, and it looked to be user error (doh!)

When I was checking for vacuum leaks, I checked the connections for both the front and rear crank case breather hoses, but I didn't reach under the manifold and check the hoses themselves. As it turned out, I was likely having a vacuum "restriction," versus an actual leak. When installed the front crankcase breather, I set the hose for the path of least resistance: a straight line to the intake pipe that it was hooking into. What I didn't take into account, however, was how close of a tolerance there was between the bottom of the supercharger and the top of the engine. So, the hose actually was pinched underneath the supercharger, unable to move, and essentially being partially crushed.

Unbolted the manifold, removed the belt, lifted the manifold, relocated the hose, and my noise is gone! Everything seems to be running well. I've sent logs to Cosworth for review just to make 100% sure everything looks good, but I'm feeling optimistic!

I've scheduled time at the dyno next week to finally strap this thing down and see how much power she makes. Once that's done, I'll format my video and finally post that up! Stay tuned folks!

[enigma]

Originally Posted by Pat

Hey guys, I live in Denver, but will be in Wichita on the 8th for a lunch meeting. I know it's a long shot, but is anyone up for an early afternoon beer that day? I have to be in KC by 5:00.

Pat, I may be game for that. I usually have a little free time in the afternoon on Fridays. Let me know when you're in KC and we could possibly meet up!

[Crestwood1001]

One of the best threads on here, sounds like this kit is top notch