HOW TO: Cosworth Oil Cooler/Intake Manifold Thermal Gasket - Focus Fanatics
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Old 04-03-2013, 11:40 AM   #1
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HOW TO: Cosworth Oil Cooler/Intake Manifold Thermal Gasket

Oil Cooler

You can purchase either the Cosworth version of this oil cooler or the Ford Escape version. The Escape version is half the price and pretty much the exact same design.

The oil cooler sits on top of the oil filter housing. You can see the difference in the pic below compared to the stock filter housing.



I removed my intake manifold to make it easier to install the coolant lines.



Once the manifold is off, remove the stock oil filter housing. There is a oil pressure sensor on the stock housing. Swap this onto the new housing. Next, install the oil cooler.





If you notice from the above pic, there is a bolt that screws into the middle on the oil cooler. The starter is in the way. Remove the starter. This will give you access to install the oil cooler bolt.

Remove the hose that is shown in this pic.



Install new rubber line.





Thermal Gasket

I bought this gasket from Ferriday Engineering out of the UK. This is a really nice thermal gasket. It isn't plastic like the Weapon R gasket.

This is pretty self explanatory. Remove the intake manifold and install the gasket. Be sure to remove the EGR tube from the head (Make sure your EGR is DISABLED).






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Old 04-04-2013, 10:45 AM   #2
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Good writeup with pics.

Quote:
Originally Posted by PSUrivie View Post
If you notice from the above pic, there is a bolt that screws into the middle on the oil cooler. The starter is in the way. Remove the starter. This will give you access to install the oil cooler bolt.
Just to nitpick, you can install the cooler on the adapter before bolting the adapter to the bolt, eliminating the need to remove the starter because of the bolt. But having the starter out helps with running the hoses.

How much did that thermal gasket run?
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Old 04-04-2013, 12:21 PM   #3
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^I tried to get the cooler in there with it bolted togoether and with all the lines and hoses it wasn't lining up properly. Since I had the IM off already there was easy access to the starter.

The gasket cost ~$100 plus shipping from the UK.
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Old 04-04-2013, 12:22 PM   #4
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oh yeah, sorry my engine is so dirty. Haven't started my Spring detailing yet ;)
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Old 04-04-2013, 01:02 PM   #5
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What exactly would this do to benefit performance or gas mileage

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Old 04-04-2013, 03:12 PM   #6
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What exactly would this do to benefit performance or gas mileage

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My opinion is nothing , will help the oil temps slightly 3-5 +/- deg, the intake manifold sitting behind a 230+ deg raid and air blowing through it the speed of the car its still going to get VERY hot even with the thermal spacer

180 thermostat and tune with fans on sooner will do way more then the oil cooler and spacer , doesnt hurt to have a little cooler oil if you track the car , for the street wouldnt be worth it

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Old 04-05-2013, 07:02 AM   #7
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Oil cooler helps a lot! On the track, my oil temps were insanely high, like 260+. The cooler is almost too effective, where on the road, it barely breaks 200.
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Old 05-13-2013, 09:18 AM   #8
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How much $ was the thermal gasket? Did you call them to order? I don't even see a cart on their site.
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Old 05-13-2013, 10:04 AM   #9
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^yeah, I emailed them.

I emailed Mike: mike@ferriday.co.uk

They cut them per order so it takes a couple days to ship it out. He was really helpful :)
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Old 05-13-2013, 02:40 PM   #10
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has there been any data recorded to support the claim that these thermal barriers actually work? I am having a hard time believing so.
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