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

[weederr33]

Man that noise is truly annoying. Hopefully it's not supposed to be like that.

[enigma]

Unlikely that I'll have an update today. Cosworth got back to be super quick as always and recommended checking for vacuum leaks and then to bleed the IC system again to make sure there isn't air in the line.

Unfortunately, I don't think I'll be able to mess with it until tomorrow.

[Kiske]

Pete, is the car ideling fine? I've had a high pitch hissing vac leak when I forgot to fully tighten a hose clamp.

[enigma]

Originally Posted by Kiske

Pete, is the car ideling fine? I've had a high pitch hissing vac leak when I forgot to fully tighten a hose clamp.

Yeah, the car idles and drives fine. And when at idle, if I hold the revs above 1200 rpm or so, the noise goes away. It's just at stop lights and right before I turn it off that the noise is present.

[Craigo]

Thanks for sharing your experience and hope you get the whine sorted soon!

Do you think the install is within the capability of an amateur mechanic?

Most i've ever done was change a turbo on an mr2 and that was hard work for me (location of the turbo didn't help!).

I'm just worried that i would not get the pulleys lined up properly and end up screwing the engine completely.

[enigma]

Originally Posted by Craigo

Thanks for sharing your experience and hope you get the whine sorted soon!

Do you think the install is within the capability of an amateur mechanic?

Most i've ever done was change a turbo on an mr2 and that was hard work for me (location of the turbo didn't help!).

I'm just worried that i would not get the pulleys lined up properly and end up screwing the engine completely.

I'm a complete spanner with a spanner and I was able to manage to do it with help. The included instructions are a bit confusing, and it probably took us much longer than other installs (I'd guess approximately 18-20 hrs total, but that's with a spark plug change, coolant flush, and thermostat change).

I think if you have enough time to go slowly and take your time, you shouldn't have an issue.

[civicdrivr]

I don't have a ton of knowledge on the Cossie setup, but I assume there is a pump for the IC water. Have you verified the noise isn't coming from that? When we installed the IC setup for my friends Innovate kit, his pump made some really weird noises until the system was fully bled.

[350matt]

agreed thats a good point
if you disconnect the pump electrically see if the noise stops?

[enigma]

Yeah, disconnected the pump and the noise persisted. Bled the system again, just to make 100% sure there wasn't air in the lines. Reattached the breather hoses, again, just in case. Checked basically every single line I could get to without removing the manifold again.

No bueno, though. It's intermittent, and if it was just a noise, I could probably swing it. However, it's thrown a CEL probably six times now, always under light throttle (usually with the cruise set and trying to increase speed with the stalk), and the code is always bank 1 too lean.

I really don't want to pull the manifold again since it's a pain, but I'm not sure what else to do at this point. :/ I was really hoping to get it on the Dyno next week, but the amount of time I have to sort this out next week is pretty limited. My only silver lining is that the car is essentially drivable without issue, and feels fine under moderate to heavy acceleration, so it's still enjoyable to drive.

[Kodename47]

There's a guy in the UK who's had his independently dyno tested:
http://www.gt86.org.uk/forums/topic/...worth/?p=40172

[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

[ajc209]

Matt you are a complete legend.

[civicdrivr]

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

As soon as I read that it threw a CEL for bank 1 lean condition, I was thinking injector seals as well.

Sent from my XT1095

[kiichiro]

subbing