Cosworth SC build...

[LucidMomentum]

Sounds great though!

[Guff]

[350matt]

hello Jerry

looking at the pictures, are the IC core bleed screws on the back?

in which case could you get away with just removing the intake rubber hose? or just loosen the intake pipe screws so you can wobble it out of the way?

[Ernie L]

Originally Posted by 350matt

hello Jerry

looking at the pictures, are the IC core bleed screws on the back?

in which case could you get away with just removing the intake rubber hose? or just loosen the intake pipe screws so you can wobble it out of the way?

Yes they are on the back
I think that might just work...worth a try..You're a clever fellow for sure. You should write manuals for Cosworth...which in this day and age, why they don't have a you tube (or it's equivalent ) installation video posted is beyond me...

I do not speak for them ,but I do believe I have some small insight as to why Rally Sport Direct did not post an instal video.

This kind of instruction with no pictures had me scratching my head.

"Disconnect the fuel fitting from the 3 pipes on the inner wing and plug with appropriately sized bolt or dowel to prevent fuel
leaking whilst working."

...we have pipes on our cars?...and wings? .. two cultures separated by a common language ha ha ha..

[weederr33]

I'm quiet certain, your build thread has become the perfect DIY for any problems we may encounter!

[Uplink]

Originally Posted by Ernie L

I think JerryIII did the installation very quickly... But I casn't say for sure..JerryIII gives new meaning to the word taciturn.
I was not able to do it in just one weekend...leaning at the waist for 5 hours in a row took out my back for a couple of days..as it is I can only go at it for a couple of hours each night after work...this is an involved installation...with sketchy fitting instructions...i.e I wasted time flipping over the banjo bolt for the hydraulic clutch. The directions said it could interfere..It's not any where near the SC (shrug) Of course I could not tell this until I had removed the banjo bolt..replaced it and bled the system of air.and installed the intake and SC....jeezez...

I know the feeling. Some days after working on the car I'll just pre-emptively take a few aspirin so I can continue working the next morning or at least move.

Is it possible that remark about interference was for the RHD models only?

[Uplink]

Originally Posted by Ernie L

Fired it up for the first time..its on high Idle...I can hear some mechanical noise from the blower.
I would like to take it for a ride but I still need to complete bleeding the inter cooler...
so what's so difficult about that you ask...well ya just gotta love the installation instructions...I spent 3 hours trying to align the bolts that hold the cool air intake pipe...two of the bolts you have to do by feel alone...while tugging on the pipe to get it to align....you get the idea...not fun...I invented a few new cuss words...anyway...after doing that I flip the page and the very last thing to do is fill and bleed the inter cooler...oh yeah ...to do that you need to open the bleed screws at the back of the intake...but first you need to remove the air pipe you just installed...#*@^&^%%$)__)(*&*&*(^%%*((( ...I will get to that tomorrow ..and take it for a shake down cruise...

Congratulations! It sounds great! The mechanical noise sounds fine. I love that it doesn't have the high pitched whine that the Innovate kit does.

Ugh, that's awful about the instruction order. You would think for the price tag and and name backing it (not to mention the fact that they are English so there is nothing to translate from say Japanese), the instructions would be very clear and concise.

[350matt]

I'm sure that Cosworth are keeping an ey on this thread and will revise their data accordingly, Ernie is one of the 1st customers after all

[Ernie L]

350Matt your idea about just removing the elbow instead of the whole intake inorder to bleed the inter cooler was a no go. Good try though.
I took it for a test ride yesterday...Joy, dejection,joy, dejection...I'm emotionally whipped
.....Upon take off there was a terrible off idle stumble..also at speed it breaks up under load unless I feather the throttle..came home found the brake booster hose barely hanging on.. Fixed it.. Joy
...took it for a ride...a little better still breaking up under load...very light throttle under cruise is fine. I also have a check engine light. It flicker at me under acceleration. Dejection
...found that I had mis attached the purge valve plumbing..fixed it JOY
...took it for a ride..no change.. Dejection

I will check for other hose related air leaks...hopefully its the rear PCV pipe...of course this requires I remove the intake cold air pipe..one more damn time..
I suspect an air leak....

[Bergen23]

Damn, sorry to hear it isn't going as well as it could be! Looking forward to seeing the finished product though!

[350matt]

Hello Ernie

with the ECUtek kit you can read off any fault codes so it would be well worth plugging it in and using the DTC tool to see whats logged

it does sound like an airleak to me though, so any any air pulled in after the MAF meter will not be 'seen' by the meter and lean the engine out

[Ernie L]

Originally Posted by 350matt

Hello Ernie

with the ECUtek kit you can read off any fault codes so it would be well worth plugging it in and using the DTC tool to see whats logged

it does sound like an airleak to me though, so any any air pulled in after the MAF meter will not be 'seen' by the meter and lean the engine out

OH LORD..

[350matt]

Hello Ernie

I had something similar on mine when I fooled around on the intake

check the big square connector at the back of the engine bay on the LHS, disconnect it and plug it back in in again and check the connectors to the lower / exh VVT actuator on the LHS

also you mentioned earlier about disconnecting all sorts when fitting it all, if the ignition was on at any time during this process, then you'll have created a fault and need to clear theses faults using the same DTC tool

[Ernie L]

Originally Posted by 350matt

Hello Ernie

I had something similar on mine when I fooled around on the intake

check the big square connector at the back of the engine bay on the LHS, disconnect it and plug it back in in again and check the connectors to the lower / exh VVT actuator on the LHS

also you mentioned earlier about disconnecting all sorts when fitting it all, if the ignition was on at any time during this process, then you'll have created a fault and need to clear theses faults using the same DTC tool

Haven't located the big black connector as yet..how ever I did check what I believe are the VVT connectors..once again you were spot on......I snapped off the RHS connector when I was installing the cosworth header. Many thanks Matt.