Cosworth Supercharger Owners Thread

[gtengr]

Well the car ran fine for about 500 miles, but today it started running rough intermittently and has the P0172 code. I pulled over and did a hand check of the vacuum attachments and intake clamps for tightness and they all seemed ok. I don't think it's a vacuum/intake leak since the problem comes and goes. Seems more like it's a sensor or electrical connection. A search points to most people having this issue with aftermarket intakes, but I'm using a stock 2017 intake and air filter with ~10k miles with the Cosworth kit. Anyone else dealt code P0172? I'm going to check the O2 sensor splice harness and the MAF, and do some datalogging tomorrow.

[sly]

Originally Posted by Seba

Hi,

what device and software do you use to collect and save live data when driving the car?

Seb

I use a laptop running Windows 7. EcuteK software loaded. Cosworth USB stick, EcuteK cable plugged into OBDII port.

[Matt@Cosworth]

Originally Posted by weederr33

I believe you can make the pulley smaller, but it would need some adapter which could protrude a bit and hit the hood potentially. Matt@Cosworth talks about it a bit somewhere in this thread as well as on the UK thread.

It's a shame you guys don't have corn power (E85). :/ And yeah going crazy on all the bare metal is no fun. When I had my kit, it felt damn good at just 280 bhp. But that's all relative.

hello gents
If you already have the small 63mm pulley then there's no room to go smaller with the standard nose gearbox on the charger
I did a mod on our dev car to increase the diameter on the stock crank pulley by about 6% with a interfered on sleeve and then resized the ancillary pullies, modified the tensioner so it can swing over more and fitted smaller idlers

this then gives you about 0.8bar of boost and 330bhp ish providing you have some steel rods in there
the biggest issue with going this route is the pulley then clouts the front cover and the boss it hits is the oil gallery route
so this has to be modified / welded up and broddled to remove the sharp corners inside - this also helps with the oil pressure at high rpms anyway so very worthwhile while you have the engine apart anyway

the charger is capable of 1.2 bar and the cooling system was all sized for this from the beginning so that will be fine


other mods to try I'd also say to investigate a larger / ported throttle body and an aftermarket air intake as with the smaller pulley you will start to get a restriction due to both of these

as ever steel rods are very strongly reccommended on this engine at anything past what our kit delivers

[gtengr]

Good info. Any recommendations on which air intake fits/works best with the kit?

[weederr33]

Originally Posted by gtengr

Good info. Any recommendations on which air intake fits/works best with the kit?

You could try the Perrin CAI. It sits in the bumper and is supposed to get the coldest air. The only pain is changing the filter come that time.

[Kodename47]

Originally Posted by gtengr

Good info. Any recommendations on which air intake fits/works best with the kit?

I've gone Airaid on the Sprintex. As this uses the OEM airbox too, it can be made to fit and no bumper removal required. I think the Skunk2 offering could be made to work as well. Most other intake kits move the MAF to the replacement tube so aren't an option.

[muckypuppy]

Originally Posted by gtengr

Good info. Any recommendations on which air intake fits/works best with the kit?

I am running the Perrin CAI and I believe Gahooligan was as well until he sold his kit. Both our cars were running the small pulley and E85 tuned by Delicious.

[Cosworth_0686]

Originally Posted by gtengr

The other pic is of the fuel connector bracket that I cut instead of using the aftermarket fitting. I preferred keeping the factory fitting and buying it again to go back to stock rather than mod the line.

I finally got the Cosworth tune installed and verified that it runs!! Now that I've started actually taking things apart, I've encountered the instruction to cut the stock fuel lines, and I'm a bit hesitant about that, as I'd like to keep that connector if possible. To verify the part that you cut instead, was it along the red line that I drew in? Does the other quick-connect fuel line just attach back to the stock location?

[sly]

Here is the way the lines are intended to be attached. I just cut the fuel line itself and left off the quick disconnect. IMO dealing with hose clamps is more convenient than dealing with the quick disconnect that needs a special tool.

The GDI fuel pump, which is the metal one with the QR code etched in it, comes with a new banjo fitting. Use some washers and a hose clamp and you're done. The other fuel line goes to the manifold injectors. Again a simple hose clamp does the job. I've never had any fuel leaks.

[gtengr]

Originally Posted by Cosworth_0686

I finally got the Cosworth tune installed and verified that it runs!! Now that I've started actually taking things apart, I've encountered the instruction to cut the stock fuel lines, and I'm a bit hesitant about that, as I'd like to keep that connector if possible. To verify the part that you cut instead, was it along the red line that I drew in? Does the other quick-connect fuel line just attach back to the stock location?

yes that's where I cut

[Matt@Cosworth]

Originally Posted by muckypuppy

I am running the Perrin CAI and I believe Gahooligan was as well until he sold his kit. Both our cars were running the small pulley and E85 tuned by Delicious.

interesting

how much power did you make?

[gahooligan]

This is true. Perrin worked great. But, i was on 93, no e85. I didn't feel like getting gas every other day...lol. Dont know how much power I made but it was fast and i had mustang drivers tell me, on track, it was fast...

Sent from my SM-N960U using Tapatalk

[Cosworth_0686]

Originally Posted by gtengr

yes that's where I cut

Thanks!

[gtengr]

Originally Posted by gtengr

Well the car ran fine for about 500 miles, but today it started running rough intermittently and has the P0172 code. I pulled over and did a hand check of the vacuum attachments and intake clamps for tightness and they all seemed ok. I don't think it's a vacuum/intake leak since the problem comes and goes. Seems more like it's a sensor or electrical connection. A search points to most people having this issue with aftermarket intakes, but I'm using a stock 2017 intake and air filter with ~10k miles with the Cosworth kit. Anyone else dealt code P0172? I'm going to check the O2 sensor splice harness and the MAF, and do some datalogging tomorrow.

Removed the MAF, cleaned it (didn't appear dirty), and the car runs great again. I get the feeling this isn't over though. Why would a MAF with 11k miles on it (always stock airbox and filter) be dirty? Are the oil vapors from the PCV able to travel upstream during certain throttle conditions and foul it?

I have an idle log, but it's 0.2 mb too big for datazap. Short term fuel trims were around -16% but varied. Sent the idle log to my tuner (Delicious).