Mill Road om 04 598300 Toyota GT86 / FRS / Subaru BRZ Stage 1 Tuning Kit Fitting Instructions - 20043610 Author: Matthew Feasey Terms and Conditions Copyright Cosworth Ltd
Kit contents: 3 exhaust system from front pipe backwards Free flow Air filter Low running temperature coolant thermostat (starts opening @ 76 ) Revised Calibration Flash lead and licence Dongle Cosworth memory stick loaded with calibration data and technical information 4-2-1 Exhaust Manifold (optional) 3 Front Pipe / overpipe combination (optional) Copyright Cosworth Ltd 2
Contents 1. Getting started - EcuTek... 4 1.1. Map switching... 7 1.2. Throttle calibration... 8 2. Exhaust System Fitting... 9 2.1. Catalyst run-in... 14 3. Thermostat fitting... 15 4. Air filter Installation... 16 5. Returns... 18 Copyright Cosworth Ltd 3
1. Getting started - EcuTek 1st visit the EcuTek website (http://www.ecutek.com/home.aspx) to download the latest version of the ECU interface software (ECUtek ProECU) onto your laptop. This must be downloaded from their site and it s recommended to periodically update this software at least once per month. Before fitting any parts the 1 st thing to do is install the software onto your laptop and connect to the car. Once downloaded there s a PDF file; Pro ECU and Software Installation within the help files which details this process Then before fitting any new parts, load in the new calibration /ROM file from those that are saved onto the Cosworth USB stick, or which have been emailed to you Copyright Cosworth Ltd 4
Depending on your market, transmission type and the level of kit that you have purchased it will be one of the following calibrations: Market With manifold Without manifold Catback only Manual Transmission Auto Transmission Original ROM ID Cosworth Cal Part no. Euro & Aus Euro & Aus Euro & Aus Euro & Aus Euro & Aus Euro & Aus ZA1JA01G 20042839 ZA1JA01G 20042840 ZA1JA01I 20043034 ZA1JA01I 20043035 ZA1JA01G 20044477 ZA1JA01I 20044478 USA ZA1JB01C 20043036 USA ZA1JB01C 20043037 USA ZA1JB01D 20043038 USA ZA1JB01D 20043039 USA ZA1JB01C 20044479 USA ZA1JB01D 20044480 Japan ZA1JA02A 20043040 Japan ZA1JA02A 20043041 Japan ZA1JA02B 20043042 Japan ZA1JA02B 20043043 Japan ZA1JA02A 20044481 Japan ZA1JA02B 20044482 Gulf ZA1JA01J 20043663 Gulf ZA1JA01J 20043664 Copyright Cosworth Ltd 5
Gulf ZA1JA01K 20043665 Gulf ZA1JA01K 20043666 Gulf ZA1JA01J 20044483 Gulf ZA1JA01K 20044484 General ZA1JA01E 20043667 General ZA1JA01E 20043668 General ZA1JA00F 20043669 General ZA1JA00F 20043670 General ZA1JA01E 20044485 General ZA1JA00F 20044486 You must select the appropriate market and transmission type for your car for the calibration to be matched. The Standard ROM file name you queried earlier should match one of the ones above. Once the calibration is loaded start and run the engine to check the installation, it should idle normally. DO NOT DRIVE THE CAR YET As the Cosworth calibration requires the fitment of the mechanical parts in order to be safe to use, driving the car on the calibration without these parts fitted will put the engine into detonation, have problems with fuel mixture and possibly damage your engine. Having established the engine starts and runs on the new cal only then fit the new parts. Please note that the calibration is locked out to prevent viewing / editing of the values in the various maps. You are of course free to create your own map but you will have to start from scratch and will miss out on the time and expertise Cosworth has put into the calibration. Copyright Cosworth Ltd 6
1.1. Map switching Using the cruise control switch the following 4 modes of operation are available The mode switching function is configured as follows: Mode 1 - Default mode upon engine restart Calibrated for 95RON Un-leaded gasoline (91 in USA) No Racerom special features enabled Mode 2 Calibrated for 98 RON Unleaded gasoline (93 in USA) Auto blip on gear down shifts enabled Rev limit increased to 7600Rpm in gears 1-3, 7500Rpm in 4 th and 7400Rpm in 5 th & 6 th Mode 3 As mode 2 with flat foot shifting function enabled Mode 4 As mode 3 with launch control enabled For automatic transmissions there is no auto blip, flat foot shift or launch control enabled, but the alternative fuel and ignition maps and gear rev limits are enabled. Copyright Cosworth Ltd 7
1.2. Throttle calibration Once the ECU has been re-flashed the throttle pedal control needs re-calibrating, this will happen normally as the car is driven over the next 20-30 miles, however you can greatly speed this process up by following this procedure: 1) Switch on ignition but do not start engine 2) Press and hold throttle down to the stop for a count of 10 3) Release pedal and repeat step 2 twice 4) Switch off ignition - done Copyright Cosworth Ltd 8
2. Exhaust System Fitting The exhaust replaces all the standard parts right up to the manifold, so back box, mid pipe, front pipe and over pipe are all replaced. The standard mount points are used throughout and no modification of bodywork is required to get it all to fit. The use of Vee band clamps allows easy fit and rotation of appropriate pieces to achieve the best possible fit. The most involved portion to fit is the new combination front and over-pipe, for this sufficient height is required to allow the pipe to angle down below the car during fitting - so it is strongly recommended that the exhaust is fitted on a vehicle 2 post lift or similar ramp. 1st remove the engine bay under shields; the aluminium plate and fibre reinforced item there are held with a combination of 12mm, 10mm AF bolts and some plastic pull out fasteners the centre of these is lifted up with a screwdriver 1st to then allow the whole fastener to be extracted. Then slightly loosen the 6 exhaust manifold nuts that secure the manifold to the engine, if fitting the Cosworth 4-2-1 tubular manifold then remove the original at this point. Figure 1 - Fitting Cosworth front pipe To assist removal of the standard over-pipe and fit the new parts on RHD drive cars, the steering column coupling has to be disconnected and the engine lifted slightly on the exhaust side. On LHD cars the column can stay connected but the engine still has to be lifted. It is recommended to use a paint marker or similar to mark the column joint before removal as misalignment on re-assembly can lead to the steering slip ring being damaged. The column joint can then be slid up on its shaft and out of the way. DO NOT TURN THE STEERING WHEEL UNTIL JOINT IS RECONNECTED Copyright Cosworth Ltd 9
Then remove the large nut securing the RHS (drivers RH) engine mount to the sub-frame Then use a trolley jack and a suitably long bar or other piece of material placed against the cylinder head or against the cylinder block by the mount Figure 2 - Lifting Engine on cylinder head This is to lift the engine up and create the required clearance there s no need to disconnect any other components please note Cosworth manifold is pictured. Figure 3 - Engine mount lifted clear of Sub-frame The front pipe can then be fed through the gap between the steering rack mount and the cylinder head - clearance is tight and the pipe has to be rotated slightly during fitment Copyright Cosworth Ltd 10
Figure 4 - Feeding in Front pipe - RHD vehicle If you re fitting the exhaust to a car with the standard manifold it is strongly recommended to remove the exhaust over pipe studs on the manifold 1 st and use the through bolts provided with the exhaust system. It is possible to get the exhaust to fit with the studs in place but it s far easier with them removed. If fitting the 4-2-1 manifold then the small plastic resonator on the underside of the inlet pipe must be removed and blanked off with the plug provided it is also recommended to slightly re-route the cooling fan wiring as pictured to move it away from the manifold. Removing the engine oil dipstick during manifold fitting also helps. Moved wiring There is also an adaptor gasket provided with the kit to mate the standard 2.25 manifold to the 3 exhaust pipe Copyright Cosworth Ltd 11
Figure 5 - Std Manifold to Cosworth Exhaust Figure 6 - Standard Manifold to Front pipe 2 Copyright Cosworth Ltd 12
Figure 7 - Front pipe junction to manifold (Cosworth manifold pictured) engine still lifted Figure 8 Front pipe in place and column re-fitted Don t forget to re-fit the column pinch bolt and double check that the steering column joint is returned to the same spline orientation you started with. Copyright Cosworth Ltd 13
Figure 9 - Rear Silencer Installation The standard exhaust rubbers are re-used throughout and it is advantageous to use some brake cleaner on the rubber when removing and fitting the exhausts this provides some lubrication for a short period of time. Once the system is fully in place, only then fully tighten the Vee-band clamps and other fastening bolts. Don t forget to re-tighten the exhaust manifold nuts once you have everything in place. 2.1. Catalyst run-in Please note if your package includes a 0.2 midpipe (pt. 20044767 or 20043858) then please follow these steps after fitting to ensure the catalyst adhesive expands correctly to lock the cat brick in place. After fitting the exhaust and ensuring all fasteners are tight, start the engine and let it idle for a time of 5 minutes Then raise the engine speed to at least 2500Rpm and maintain this rpm for a minimum of 1 minute Then drive the car for a further 3 minutes but do not exceed 3000rpm This completes the catalyst run-in and the car can then be driven normally thereafter, it only needs to be performed once, just after fitting and not repeated. The important aspect of the process is to allow the new catalyst to warm slowly and not drive off immediately after fitting at 7500rpm. This heat cycle will cure the cat brick adhesive and lock the catalyst in place If this is not performed then you run the risk of the catalyst rattling about and becoming damaged in a short space of time Copyright Cosworth Ltd 14
3. Thermostat fitting With the under-shields removed the thermostat is accessed from under the engine you remove this housing Figure 10 - Thermostat housing All bolts are accessible even with the standard manifold in place; the new thermostat is a like for like replacement. You will lose some coolant during this process so be prepared to have to replace it and then bleed the engine from the high points on the heater hoses at the back of the engine bay. Typically one heating up / cool down cycle is required to remove all the air from the system and allow the coolant overflow / siphon tank to work and set the correct level. Double check coolant levels before giving the engine any hard work. Copyright Cosworth Ltd 15
4. Air filter Installation Fitting the air filter is a like for like replacement of the standard part Figure 11 - Fitting Cosworth Filter - note pleat direction Figure 12 - Air filter corner note matching radius Copyright Cosworth Ltd 16
Figure 13 - Filter in place Copyright Cosworth Ltd 17
5. Returns Should you find any aspect of the part that is not satisfactory then please fill in the returns form below and arrange for the part to be returned to the dealership you purchased it from Returns Material Authorisation Form Please ensure all parts to be returned have been pre-qualified for warranty work prior to submitting this form. Company: Contact name: Address: City: State or Province: Postcode: Email address: Phone: Vehicle Make: Vehicle mileage: Vehicle year & model: Vehicle Modifications: Qty Part no. Part name Issue Purchase date Mileage on part Copyright Cosworth Ltd 18