Hi all, New member here and need a bit of tuning advice, I have a 3 door Cosworth which is stage 1 and have been in storage for a while, I'm getting it back on the road to use and want to make it stage 3, I've bought a few bits 803 green injectors group a fuel pump and wiring loom 3 bar map sencor 31 actuator ecu with chip, I want to get a uprated front mounted intercooler but do you guys know or recommend a intercooler that is a direct fit or which one is the best to use, any info would be much appreciated thanks.

 

I would be careful, as standard the head gasket is a weak point, also the health of the engine needs to be assessed.

Fuel pump isn't required, BUT it's wiring degrades, which means the pump cannot draw the power it needs, as a result the engine does not get the fuel it needs = meltdown.

This along with the fan wiring are two common issues, rewire kits are available for both.

There are plenty of RS 500 style intercoolers, which are a direct fit.

I would advocate someone check fuelling and set afterwards.

Martin

 

Ok thanks for the reply I forgot to mention the engine has been rebuilt a while ago with a group a head gasket so should be ok but will have the wiring ect checked when we are doing the rest and will look into the rs 500 intercoolers

 

Airtec do a good RS 500 style for reasonable money, others like pace etc can also be picked up 2nd hand. Spec R is the Daddy but can be delays and over Ł1000 in cost.

 

Airtec will be fine for your needs.

Please take the advise of Martin above also is it a genuine 3 bar map sensor and who's map / chip are you using?

Trust me it makes all the difference having the correct map for the turbo and associated mods not just a generic greens map.

 

Thanks for the replys it sounds like a pace/airtec rs500 style will be just fine and to be honest I'm doing the stage 3 set up half because I want to and half because I'm hoping it will cure a problem what it's had ever since I bought it bit of a long story but I bought it from a bloke that could never get it running right it can be fine for around 5 miles then all of a sudden it just dumps fuel in the engine and you have to pull over and rev the nuts off it until it clears it then it's fine until it decides to do it again which could be 20 miles later it's been rebuilt tried all the sensors ect hoping it could be the fuel pump wiring plus someone has suggested it could be the wrong chip in the ecu telling it the wrong fuel for the injectors ect

 

It is a genuine map sencor and it's been a long time since I bought the parts as it's been in storage as got fed up with it as could never cure it but pretty sure it's a Collins chip

 

Grey injectors i guess.???

 

I would get it live mapped, it's a long trip but MSD would transform the car.

 

The above is a good idea and Stu will sort out any other issues that arise.

 

If you want to keep you car looking original, if you are looking to run about 300 bhp, you could use a Saph 4x4 standard intercooler, fits in the standard position as std 3dr one and looks practically the same.

 

Seen 340bhp with no issues on a 4x4 cooler.

 

Oh right might look into the saph cooler as well then and if this doesn't work then will definitely be taking it to msd this car is so frustrating lol but thanks again for all the replys

 

Just one last thing is there a very noticeable difference in performance between a stage 1 and stage 3 set up

 

Yes.
Tbh save your time and effort and take it to msd once you have fitted parts.
Your car will be transformed..........

 

It's not a fuel supply issue, by the fact you have the opposite effect, i.e. too much fuel.

Stage 1 is just a different calibration, which is what you believe yours is.

I don't believe this to be the issue either, I would advocate someone looking at it, the fact it's not running right now means further tuning would be a bad move.

Martin

 

That might be the best thing to do is take it to msd with the parts and get it set up correctly I think

 

It's a pain given your location, but it's a good excuse to combine it with a mini break etc.

I would like to take mine to MSD at some point, just Geography that has stopped me from doing so.

Martin