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Old 10-21-2012, 01:27 PM   #1
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Cosworth IM install - what a NIGHTMARE

Posting this for reference/search purposes and I have a question for those of you that have installed this item.

Now, I have been working and modifying cars and trucks for 16 years. Everything from engine and cam swaps, intake swaps, trans rebuilds, etc. The Cosworth intake manifold is the second worst install of any part that I have ever installed (first worst was a set of bassani equal length headers on a lightning).

First of all, the Cosworth instructions show how to install the manifold with the engine pulled. Well, any idiot can bolt on an intake with the engine out of the car....thanks for nothing Cosworth.

Note, if you have cruise most focuses need to modify or buy a special kit in order for you to retain cruise control. of course, this isnt in the instructions. They just say "call cosworth if you wish to retain cruise control with this intake." thats a crock of crap

Next: you are supplied with a 12mm brass button. Hmmmm, where does it go? Its no where in the structions. Oh, look there is a hole that is kind of threaded, but kind of not. Fast forward to an hour of tap this plug into that hole. again, nowhere in the instructions does it say to do this.

Next: since the cosworth intake eliminates the butterfly flaps on both 2.0 and 2.3 intake manifolds, you will be eliminating the vacuum hose assembly that controls these butterfly flaps. I belive there is a sensor that gets deleted guessed it....not in the instructions.

Onto bolting on the intake.....good luck. Now, I know a lot of people have done this without issue. I am not one of those people. There is a sensor on the PS pump hose that the manifold will not clear. It is RIGHT up against the sensor. I had to use a screwdriver in order to get the holes lined up on the intake because I couldnt move the intake over far enough (this is on an 05 model).

The pcv bung supplied would not fit the tapped hole on the intake manifold. I tried and my friend tried. I had to cut the pcv bung and JB weld it to the intake. Let me say, that thing is never coming off now. Also, since you have to trim the PCV hose....disregard the instructions. I cut mine per the spec supplied...and even left it a little bigger. When I went to install it, it was over 1.5" short! I had to order a new hose.

I had to reshape the dipstick tube in order to get it to fit correctly.

There are three bolts that go on the bottom of the intake. The one near the throttle body is a piece of cake. The center bolt...well, I had to use a pair of needlenose pliers and gently get the bolt started. Then you can start to torque it down....about 1/16" of a turn at a time. But, at least you can get to it.
Now, the bolt near the PS pump has me at a complete loss. I have tried to get to it from every angle. I can barely see the hole, let alone get to it. The only way I can see to get to this is to completely remove the ps pump in order to get access to that bolt. Now, if that is the case, that is not in the instructions. If this must be done, its going to be an additional PITA because the PS fluid will have to be drained, hoses removed from hardline....because you cant access the bottom PS bolt unless you remove all of that.

So, here I sit. 5 bolts snugged down, but not tightened down with no way to get to the final bolt.

Had I known it would be this difficult, I would have taken it somewhere to install it.....or built my own custom sheetmetal intake.

So, does anyone know how to access the bolt near the PS pump?!

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