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Cosworth Stages 1 1+ 2 3 3+ 4 5+ 6 7 |
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Please note that we can supply you with these conversions for DIY installation and setup, but would advise you to have your car converted professionally by us, as not only do we fully set up the car for fueling and boost, but we also custom map EVERY conversion so that the engine mapping is perfect for your individual setup.
Stage
1 This
conversion is a huge improvement over standard and involves the fitment of
a new "chip" to the ECU and the fitment of a new wastegate
actuator. We recommend a genuine Garret –31 item as these are superior in
quality and operation to the usual alloy type. In addition we advise the
fitment of a K&N type panel filter in the standard air box. The boost is
then set to 16psi, the spark plugs either changed or gapped as
appropriate and along with a full setup to adjust fueling and boost around 270bhp/270lbf ft can be expected.
During the setup Stage
1+ This is a recent development of the stage 1 conversion and takes the std engine to an even higher state of performance. This conversion however can only be performed on original engines in excellent health or those which have undergone a complete rebuild. Likewise the turbo must be in excellent condition and preferably be fitted with a 360degree thrust bearing. Again a new "chip" is fitted to the ECU along with a Garret -31 actuator, and suitable plugs fitted and gapped if required. For 2wd cars I advise the fitment of a 4X4 Sapphire Intercooler. Coupled with a full setup and alterations to the mapping as required to suit your car, this allows the car to run in excess of 22psi between 2500rpm and 5000rpm, then dropping to 17psi by 6000rpm and finally tailing to 14psi at the 7000rpm limiter. This setup normally results in around 295bhp/320lbf ft. Stage
2 This level of tune is now overlooked because the cost is so similar to the stage 3. It involves the fitment of Bosch 355 injectors and utilises the stage 1 chip. In this situation the power output can be regarded as the same as either Stage 1 or 1+. Stage
3 This is the most common level of tune found on modified Cosworths. This involves a new "chip" fitted to the ECU calibrated for a 3 bar map sensor and a new set of Bosch 803 injectors. Coupled with a Garret –31 actuator and K&N panel filter the boost can now be set to peak around 24psi and hold 22psi and around 320bhp/320lbf ft is achievable. Again the car is fully road tested to check fueling and boost as well as any alterations to the mapping as required. At this level we advise the fitment of a new breather system, though it isn't strictly necessary if the existing system and engine are in perfect condition. Please note however that the standard 2WD turbo and intercooler are not suitable for running a constant 22psi and for this conversion will be set to peak at 22psi put tail to around 18psi to preserve the turbo. We would advise the fitment of a 4X4 intercooler and suitably specified hybrid T3 turbo for 2wd cars that wish to run higher boost. It is also worth fitting a free flow 3inch bore exhaust at this stage, and we can supply suitable stainless steel systems. (Our exhausts use 3inch bore in the silencers as well, unlike some off the shelf items!) Stage
3+ This conversion is becoming even more common as many owners choose to take their power outputs further. We now fit a new 0.55 T34 (or 0.48 T34 if maximum punch is required) supplied through Turbo Technics, and at this level we advise the fitment of an RS500 style intercooler and we supply our own custom design made for us by Radtech. Still utilising Bosch 803 injectors and a 3bar map sensor, Denso IK27 spark plugs are fitted along with a Group A coil and coupled with a full setup and mapping session the boost is raised to 26psi and around 360bhp/340lbf ft can be expected. In addition we advise that the head gasket is replaced at this power level, and we now advise that the block is wire rung, the head face skimmed if required and reassemebled with a YBO611 headgasket. Wire ringing involves machining of the block face to insert a 1mm wire that protrudes slightly above the block face to both increase cylinder head fire ring clamping and prevent the head gasket from blowing outwards! Along with this conversion it is often necessary to rewire the fuel pump and if necessary replace with a Group A Bosch 044 item. (033 in case of escort Cosworth) All other components such as exhaust and breather should now be uprated as a matter of course and again if required the radiator changed to an uprated alloy type. We supply our own range of radiators custom made for us by radtech in a range of core thickness from 50mm to 75mm!! Stage
4 For this level we fit Bosch 403 injectors, (Sometimes 400's at customer request) and again use the 3 bar map sensor. The head gasket as mentioned in the Stage 3+ setup should now be upgraded with wire ringing and a YBO611. As another option we do also recommend using the Mountune 4 layer WRC metal head gasket, but this does require both the block and head face to be machined correctly which will, if not correct, require the engine to be removed from the car and stripped for machining. It is still permissible to maintain the standard 8.0:1 compression ratio, but the turbo and intercooler must be changed. The RS500 style intercooler and 0.55 T34 can both be used from the stage 3+ setup if upgrading from this setup. However at this point the engine breather system must be uprated and a free flowing 3 inch exhaust fitted. We can of course supply all these parts as required.
All
engine ancillaries such as boost hoses must also be suitable for the
increased boost and it is essential the engine is in excellent condition.
With the boost set to peak around 30 psi and hold 28psi the vehicle is now
fully setup and custom mapped and around 380bhp/370lbf ft can be achieved. Stage
5 Keeping with the Bosch 403 injectors and 3 bar map sensor, the cylinder head is now removed from the car. We port the head to our stage 1 specification along with it being fully recondition with new valves and valve springs as required. Provided the bottom end is in excellent condition (If not it will be rebuilt) the block will either be wire rung with a YBO611 headgasket or changed to a Mountune 4 layer WRC steel gasket. We reinstall the stage 1 head with a pair of our own cams and new followers timed in correctly using verniers. A 2wd exhaust manifold is used along with a spaced 4X4 plenum and std throttle body, fitted to a ported inlet manifold to suit the stage 1 head. The turbo is now changed to one of our custom built internally gated Garrett GT30's, and all anciliaries such as intercooler, radiator, breather, clutch and fuel pump/wiring must be suitable or upgraded. The vehicle is custom mapped on the road and boost set to around 28psi. Power is around 430bhp with 380lbf ft torque. Stage 5+
With
boost peaking at around 34psi and holding 30psi through to the 7600rpm
limit, the vehicle is fully setup and custom mapped on the road and
power is around 480bhp with over 400lbf ft of torque, and is our modern
day equivalent to the old T4 setup but without the lag! (We do still use
T4's in many applications where appropriate so call or email to discuss
your requirements!) Stage 6 Using the stage 5+ engine as basis, the 2wd exhaust manifold is now modified to accept an external waste gate. The turbo is swapped to an externally gated GT30 with larger exhaust housing and a turbosmart waste gate is used. This requires a custom down pipe to be made to allow either the external waste gate to plumb back into the main exhaust, or an external waste gate "screamer" pipe to be fabricated. The intake system is now changed to a larger plenum, and allthough not essential the cams should be changed to a pair of our more radical profiles. It is at this level we offer both hydraulic and solid lifter cam options. The cylinder head must now be re-ported to our stage 2 specification (up to 600bhp) and again either wire rung with a YBO611 or a Mountune WRC steel head gasket. Since an external wastgate has now been fitted a new boost control system is fitted to allow accurate boost mapping. The vehicle is again fully setup and live mapped on the road, boost is again set to peak at 34psi and hold 30psi. Power has now risen to around 520bhp and 420lbf ft. Stage 7 Beyond 550bhp there are many options depending upon budget and your requirements. We can offer engines ranging from more traditional Rally-X specifications to our own specific conversions. All conversions at these power levels utilise custom made steel cranks, rods and forged pistons. We offer big valve heads using valves we have had custom made specifically for turbocharged applications, along with solid lifter cam profiles, custom tubular exhaust manifolds and a whole range of options of turbo! Realistically we consider 700bhp about the maximum for any kind of reliability (especially as a road car where 20,000+miles are expected) but we can exceed this level if required!! Everything around the engine such as transmission, brakes, clutch (we fit our own twin and triple plate 7 1/4" hydraulic conversion at this level) and cooling must be capable of the job but again we can supply everything you require. As always call or email us to discuss your requirements.
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