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AllCarFan 10-21-2012 01:27 PM

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?!

PSUrivie 10-21-2012 02:14 PM

The little support bracket that comes with the intake should go on last. With it removed, it will give you enough clearance to get to the bolt. I had to use a 1/4" drive ratchet with a short handle and a deep socket. That gave me enough clearance to tighten the bolt up. This is definitely a bolt you need to get to from underneath the car.

The PS pressure sensor you can twist a little to give you the clearance to bolt the mani up.

Didn't you get a dipstick with your intake mani? Mine installed fairly easily. The dip stick bracket didn't line up perfectly though. I just had to bend the dip stick a little for it to line up.

AllCarFan 10-21-2012 02:17 PM

There is no way to get to that last bolt from underneath on my car. I dont have the support bracket installed. I will see if I can get a 1/4" drive ratchet, rather than my 3/8" up in there. There is a hose or two in the way.

Yes, I got a new dipstick, but it needed to be bent nearly 2" to get it to fit right. If I know Ford, every one of these engines was built slightly different!.

AllCarFan 10-21-2012 03:36 PM

I finally got the bolt started. I had to close my eyes and feel around. My forearm is too big to really get up in there.

One other thing I needed to mention....these orings that are supplied are crap. They dont stay in the grooves when you install the intake. I had to scotch tape them in there. The tape will end up burning off.

SaleenT121 10-21-2012 04:10 PM


Originally Posted by AllCarFan (Post 4416097)
I finally got the bolt started. I had to close my eyes and feel around. My forearm is too big to really get up in there.

One other thing I needed to mention....these orings that are supplied are crap. They dont stay in the grooves when you install the intake. I had to scotch tape them in there. The tape will end up burning off.

I know im late now but i removed my headlight to get to that bolt by the PS pump. I hope u changed the PVC while u could cause it will fail later on.

AllCarFan 10-21-2012 04:18 PM

I changed the PCV hose, but not the PCV valve. If/when it fails, I will probably just delete it. After dealing with this intake, getting it back off and back on will be fairly easy.

FR2oh 10-21-2012 04:36 PM

When i changed intake manifolds on mine i just tore the whole front off the car, bumper headlights, radiator, and core support, sounds like alot but takes about 30-45 mins then its wide open you can access it with ease.

felixthecat 10-21-2012 06:29 PM

Wow thats some work to install that manifold. Like FR2oh, I would of pull the front end off. I removed my bumper yrs ago to remove the stock air cleaner & all the ducting to install a Steeda sri. Thats right about pull the p/s bolt on the bottom, you have to undue the hose to get the bolt out. I had to pull my front cover,= I forgot about the chain tensioner, when I installed my crane cams. It just added a couple more hrs. I been eyeing that manifold for yrs. Let us know how it runs. Subscibed.

PSUrivie 10-21-2012 06:43 PM

For the O rings, use some spray some white lithium grease into the grooves and them insert the rings. The grease will hold them in place while you install the mani.

AllCarFan 10-21-2012 07:02 PM

Even with the bolt started, there is no way for me to get a wrench on it to turn it. If I was a 6 year old girl, i might be able to get my hand on there to turn, but other than that, I dont know how to do this. Maybe if I had a small, 1/4" air ratchet, it would work, but I dontknow.

I pray that I do not have to remove the front end, drain the radiator, remove radiator, drain PS fluid, remove hoses from pump, remove the PS pump...only to get to this damn bolt.

I would NEVER...EVER have bought this ridiculous intake had I know this is what was involved for the install.

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